Modern diesel technology : Electricity and electronics

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MODERN DIESEL TECHNOLOGY:

ELECTRICITY & ELECTRONICS

2ND EDITION

Joseph A. Bell

Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States

Modern Diesel Technology: Electricity

& Electronics, 2nd Edition

Joseph A. Bell

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Dave Garza

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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

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

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

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

Preface for Series

The Modern Diesel Technology (MDT) series of

textbooks debuted in 2007 as a means of addressing

the learning requirements of schools and colleges

whose syllabi used a modular approach to curricula.

The initial intent was to provide comprehensive coverage of the subject matter of each title using ASE/

NATEF learning outcomes and thus provide educators

in programs that directly target a single certification

field with a little more flexibility. In some cases, an

MDT textbook exceeds the certification competency

standards. An example of this is Joseph Bell’s MDT:

Electricity & Electronics, in which the approach

challenges the student to attain the level of understanding needed by a technician specializing in the key

areas of chassis electrical and electronics systems—in

other words, higher than that required by the general

service technician.

The MDT series now boasts nine textbooks, some

of which are going into their second edition. As the

series has evolved, it has expanded in scope with the

introduction of books addressing a much broader

spectrum of commercial vehicles. Titles now include

Heavy Equipment Systems, Mobile Equipment Hydraulics, and Heating, Ventilation, Air Conditioning &

Refrigeration. The latter includes a detailed examination of trailer reefer technology, subject matter that

falls outside the learning objectives of a general textbook. While technicians specializing in all three areas

are in demand in most areas of the country, there are as

yet no national certification standards in place.

In addition, the series now includes two books that

are ideal for students beginning their study of commercial vehicle technology. Thes two titles (Preventive Maintenance and Inspection and Diesel Engines)

are written so that they can be used in high school

programs. Each uses simple language and a nononsense approach suited for either classroom or selfdirected study. That some high schools now option

programs specializing in commercial vehicle technology is an enormous progression from the more

general secondary school ‘‘shop class’’ which tended

to lack focus. It is also a testament to the job potential

of careers in the commercial vehicle technology field

in a general employment climate that has stagnated

for several years. Some forward-thinking high schools

have developed transitional programs partnering with

both colleges and industry to introduce motive power

technology as early as Grade 10, an age at which

many students make crucial career decisions. When a

high school student graduates with credits in Diesel

Technology or Preventive Maintenance Practice it

can accelerate progression through college programs

as well as make those responsible for hiring future

technicians for commercial fleets and dealerships

take notice.

As the MDT series has evolved, textbooks have

been added that target specific ASE certifications,

providing an invaluable study guide for certified

technicians who are adding to their qualifications

along with College programs that use a modular

learning approach. Electronic Diesel Engine Diagnosis

(ASE L2), Truck Brakes, Suspension, and Steering

Systems (ASE T4 and T5) and Light Duty Diesel Engines (ASE A9) detail the learning outcomes required

for each ASE certification test.

Because each textbook in the MDT series focuses

exclusively on the competencies identified by its title,

the books can be used as a review and study guide for

technicians prepping for specific certification examinations. Common to all of the titles in the MDT series,

the objective is to develop hands-on competency

without omitting any of the conceptual building blocks

that enable an expert understanding of the subject

matter from the technician’s perspective. The second

editions of these titles not only integrate the changes in

technology that have taken place over the past five

years, but also blend in a wide range of instructor

feedback based on actual classroom proofing. Both

should combine to make these second editions more

pedagogically effective.

Sean Bennett 2012

vii

Preface

The primary purpose of this textbook is to provide

an understanding of electricity and electronics to the

extent required by an entry-level truck technician. The

focus throughout this textbook is the fundamental

principles of electricity and the application of these

principles to the diagnosis of modern truck electrical

systems.

AUTHOR’S BACKGROUND

My career in the automotive industry began at a

service station with a garage when I was still in high

school. After graduation, I joined the military where I

became a truck technician. Following my military

service, I worked as an automobile and truck dealership technician throughout the automotive electronics

revolution of the 1980s. Like most other technicians of

that era, my electrical skills were lacking, so I decided

to take some college courses to increase my knowledge

of electricity and electronics. After several years of

part-time study while still working full-time as a

technician, I was able to complete a bachelor’s degree

in Electrical Engineering Technology from Purdue

University. I then began working for International

Truck and Engine Corporation (Navistar) and became

the lead electrical test engineer. Some of my projects at

International include the High Performance Truck series, 2007 emissions, and ProStar models. I am currently a senior diagnostic engineer for a manufacturer

of diesel engines.

REASONS FOR WRITING

THIS BOOK

Trucks of the past had very simple electrical systems. Anyone who has looked at the electrical system

on a modern truck knows that this is no longer true.

One of my main reasons for writing this book is to

provide a text designed specifically for truck technicians-in-training that stresses the importance of a

strong knowledge of the fundamentals of electricity.

As a former technician, I have experienced first-hand

the anxiety that electrical problems can present. The

goal of this book is to help alleviate the anxiety associated with troubleshooting a modern truck electrical

system problem by explaining some of the mysteries of

electricity and electronics.

DETAILS OF THE TEXT

The material in this textbook is presented using

easy-to-understand analogies whenever possible.

These analogies are comparisons of electrical concepts

with concepts that are much easier for most students to

understand, such as hydraulics and pneumatics. Math

and non-relevant theory is kept at a minimum, but

Extra for Experts sections appear at the end of most

chapters where more challenging topics are addressed.

The text also addresses the disassembly and testing of

cranking motors (starters) and alternators. Repairing or

rebuilding of cranking motors and alternators was

common in truck repair facilities of the past. These

days, inoperative cranking motors and alternators are

usually just replaced with new or remanufactured

units. Material covering the inner workings of

cranking motors and alternators was included in the

text because many experienced technicians have indicated that it is still important for modern truck

technicians to understand how these electrical devices

function. This is true even though the cranking motor

or alternator is probably going to be replaced anyway.

An understanding of the inner workings of cranking

motors and alternators should help technicians to

troubleshoot problems associated with the cranking

and charging systems. This same philosophy is carried over to the coverage of electronic modules found

in modern trucks. Like cranking motors and alternators, electronic modules are almost never repaired

by truck technicians. Even so, the text describes some

of the components that are contained within typical

truck electronic modules and the manner in which

these components interact with other devices in the

electrical system. A basic understanding of what is

occurring inside these electronic modules should help

viii

technicians to troubleshoot modern truck electrical

systems.

NEW FOR THE SECOND EDITION

Enhancements for the second edition include the

addition of a new chapter on electronic diesel engines

with discussions on EPA 2007 and 2010 exhaust

emissions including heavy-duty on-board diagnostics

(HD-OBD). Hybrid electric vehicles are also introduced along with other emerging technologies. The

chapter on body control modules includes updated

material with enhanced coverage of the Freightliner

multiplexed electrical system.

SPECIAL NOTATIONS

Throughout this book, the text contains special

notations labeled Important Fact, TechTip, Caution,

and Warning. Important Fact indicates that the information is vital for understanding a concept and is

something that you should try to commit to memory.

This information will usually come up again in later

chapters. TechTip indicates that the information is

something that you may find useful in the future when

actually working as a technician. Caution is given to

prevent making a mistake or error that could damage

equipment or result in personal injury. Warning is

used to emphasize that serious personal injury or injury

to others could occur if the information is not heeded.

ACKNOWLEDGMENTS

I would like to thank the engineers, mechanics, and

technicians who have mentored me throughout my

career both as an automotive technician and as an

engineer. I would also like to recognize some of my

favorite professors from Indiana University–Purdue

University at Fort Wayne, including Hal Broberg,

Ph.D., Peter Hamburger, Ph.D., Thomas Laverghetta,

MSEE, Paul I-Hai Lin, MSEE, and David Maloney,

Ph.D. Thanks to Phil Christman and Jeff Calfa of

Navistar for artwork permissions, including the cover

art for the MDT series.

This second edition is dedicated to my grandsons

Ethan, Jackson, John, and Jason.

CONTRIBUTORS

Jay Bissontz, PL

HEV Program Manager

Navistar

Piotr Dobrowolski

Product Manager

Continental Corporation

Ron Friend

Engineer

Bendix Commercial Vehicle Systems

Deborah Fogt

Senior Engineer

Cummins Inc.

Clive Harley

VP Engineering

Prestolite Electrical

Drew Harbach

Senior Product Engineer

Peterbilt Motors Company

Daniel Hilaire

Senior Master Technician

Navistar

Scott Kammeyer

Senior Engineer

Caterpillar Inc.

Edward Kelwaski

Senior Electrical Engineer

Heil Environmental

Rich Michels

Navistar Master Technician

Brattain International Trucks

Dustin Moehrman

Freightliner Technician

David Perdue

Electrical Test Engineer

Navistar

Raymond Peterson

Director – Locomotive Engineering

Union Pacific Railroad

REVIEWERS

Cynthia Bell

Physics, Chemistry, and Science Teacher

Don Bosco High School

Matt Gumbel

Senior Engineer

Navistar

John Murphy

Professor

Centennial College

School of Transportation

Aaron Dix

Madison Area Technical College

Jesus Acevedo

Western Technical College

Bill Yokley

Guilford Technical Community College

CHAPTER

1 Safety

Learning Objectives

After studying this chapter, you should be able to:

n List proper attire for working in a truck repair facility.

n Choose which type of protective eyewear should be worn for a given task.

n Describe some of the hazards associated with high voltages.

n Discuss some of the hazards associated with hybrid trucks.

n Explain the purpose of the third terminal on a North American 120V AC electrical

outlet and why it is important.

n Explain personal safety precautions, including the use of MSDS.

INTRODUCTION

The importance of safe work practices is something

that cannot be overemphasized. Many truck technicians are paid on a flat-rate pay system or similar

performance-based pay system. This may tempt you to

cut corners and take risks when it comes to safety in an

effort to make rate. However, a work-related injury

can leave you sitting at home or in the hospital and

earning little or no pay (or worse).

Most shops take safety seriously because they

know that an injured technician results in a loss of

shop revenue and that good technicians are difficult to

replace. Additionally, job-related injuries may cause

governmental agencies such as the U.S. Occupational

Safety and Health Administration (OSHA) to inspect

the facility and levy fines for safety violations. However, each technician is ultimately responsible for his

or her own personal safety.

PROPER ATTIRE

Proper clothing for a truck technician is very

important to minimize risk of injury. It is often

necessary to work near moving components when

troubleshooting electrical problems. Clothing should

be properly fitted and worn correctly. Loose-fitting

clothing or untucked shirttails can be caught in

moving components, resulting in serious injury.

Trucks have steps that must be climbed to enter the

Key Terms

electric shock

ground fault circuit interrupter

(GFCI)

material safety data sheet (MSDS)

original equipment manufacturer

(OEM)

cab or to work at the back of cab. It may also be

necessary to climb a ladder to work on a trailer

electrical problem. Loose-fitting clothes can snag on

ladders, causing a fall.

Jewelry should not be worn while you are

working on trucks. Rings, when caught on moving

components, have resulted in the loss of fingers.

Chains and bracelets can easily catch on a moving

component, resulting in severe injury to the technician. Jewelry is also made of metals such as gold and

silver, which are excellent conductors of electricity.

Jewelry can act as a short circuit between a battery

positive terminal and the truck sheet metal or frame,

referred to as chassis ground, resulting in serious

burns.

Long hair also creates hazards when you are

working around rotating components. Tie up long hair

securely or tuck it into a cap.

Proper footwear is also very important for truck

technicians. Truck components are typically very

heavy. Sandals, athletic shoes, and similar leisure

shoes have no place in a truck garage. Dropping a

heavy component such as a starter (cranking) motor

on your foot may cause serious injury. Work boots,

especially steel-toed safety shoes, offer some level of

protection. Work boots (Figure 1-1) should have slipresistant soles because garage floors are often

slippery.

Gloves are also very important. Truck technicians

must use their hands more than just about any other

body part. Trucks have many sharp edges that can

cause severe cuts. Gloves designed specifically for

automotive technicians have been introduced in

recent years. Gloves reduce cuts and scrapes while

improving grip for many general tasks. Welding, cutting, and heating using torches are common tasks for

truck technicians. Specialized welding gloves should

be utilized when working with a flame or when

welding to prevent serious burns.

Working with chemicals, including waste oil and

diesel fuel, requires the use of special chemicalresistant gloves. These not only protect against skin

damage such as chemical burns but also prevent

harmful chemicals from being absorbed into the body

through the skin. Years of accumulating chemicals that

were absorbed through the skin into the body may

cause cancer or other illnesses.

Always select the correct type of glove for the job.

Consult the Internet links at the end of this chapter for

more information on glove selection.

Eyewear

Proper eyewear is probably the single most important piece of safety equipment for a truck technician. Squinting or looking away when grinding or

cutting without wearing proper eye protection is just

asking for an eye injury. Different tasks require different levels of protection. If you wear prescription

glasses and need them to see while you are working,

you should obtain prescription safety glasses. These

should have side shields that can be attached to the

frames. If you do not wear prescription glasses, clear

plastic safety glasses with side shields like those

shown in Figure 1-2 should be worn at all times when

working in a truck garage, even when not performing

work such as metal cutting or grinding. Truck repair

often requires working on a creeper underneath a

truck. Road debris such as sand and salt can easily fall

into your eyes.

Figure 1-1 Protective footwear.

Figure 1-2 Safety glasses.

2 Chapter 1

Safety glasses alone may not provide adequate eye

protection when performing cutting or grinding or

when working with chemicals or batteries. Safety

goggles, like those shown in Figure 1-3, should be

worn when performing these types of tasks.

A safety shield, shown in Figure 1-3, is not a

substitute for safety glasses or safety goggles. The

safety shield provides an added level of eye protection

and protects the face when cutting or grinding and

when working with some chemicals.

Your shop or school should have an emergency eye

wash station like that shown in Figure 1-4. Make sure

you know where it is located and test it at least

monthly to ensure that it works.

Hearing Protection

Most truck shop operations are very noisy.

Prolonged high noise levels can result in a substantial hearing loss, which you may not realize

until it is too late. Earplugs or earmuffs should be

worn when working in high-noise environments

(Figure 1-5). This includes working near a running

diesel engine.

ELECTRICAL SAFETY

Following safe practices when working with truck

electrical systems can minimize your risk of injury.

You should return to this section for review after

studying Chapter 2 and Chapter 3.

Electric Shock

The first thing that may come to mind when discussing electrical safety is electric shock. Most

everyone has probably experienced some level of

electric shock. Walking across a carpeted floor in hardsoled shoes and then touching a metal object causes

you to experience a level of electric shock.

The nervous system of the body uses voltage

impulses to control muscles. The amplitude of these

voltages utilized by the nervous system is very low.

Making physical contact with voltage sources outside of the body can cause these nervous system

voltages to be overridden. This can cause muscles to

contract involuntarily, such as those that control the

fingers and hand. Making contact with a sufficient

voltage source with the hand can cause the hand to

form into a fist. It may not be possible for the person

receiving the shock to release the fist, thus

Figure 1-3 Safety goggles and full face shield.

Figure 1-4 Emergency eye wash station.

Figure 1-5 Hearing protection.

Safety 3

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Modern diesel technology : Electricity and electronics

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