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Preface ix
Acknowledgments xi
About the Author xiii
Fundamentals of Electricity 1 (22)
Fundamentals of Electricity 1 (1)
Introduction 1 (1)
Conductors 2 (1)
Use of Electrical Energy 3 (1)
Basic Electrical Symbols 4 (1)
Resistors 4 (1)
Insulators 5 (1)
General Theory of Electricity 5 (1)
Electron Flow in a Copper Wire 6 (1)
Voltage 6 (1)
Resistance 6 (1)
Types of Electrical Circuits 7 (1)
Current Flow 7 (1)
Basic Electrical Flow 7 (1)
Positive-versus Negative-Ground Electrical 7 (1)
Systems
Ohm's Law 8 (1)
Series Circuits 9 (2)
Parallel Circuits 11 (1)
Voltage Drop 12 (1)
Series-Parallel Circuits 13 (1)
Comparison of Circuits 13 (1)
Conductor Properties 13 (1)
Wiring Recommendations 14 (1)
Wire Color Code 15 (1)
Electricity and Magnetism 16 (4)
Questions 20 (3)
Introduction to Electronics 23 (23)
Various Electronic Devices Applied to Cars 23 (4)
and Trucks
Steps in Producing a Microchip 27 (4)
Basic Electronic Control Devices 31 (1)
Current Flow and Semiconductors 32 (1)
Diodes 32 (3)
Zener Diodes 35 (1)
Transistors 36 (2)
Bipolar Transistors 38 (1)
Transistor Amplifiers 39 (1)
Light-Emitting Diodes 40 (1)
Photodiodes 41 (1)
Photoconductive Cells 41 (1)
Phototransistors 41 (1)
Using an Ohmmeter 42 (1)
Testing Diodes and Transistors 42 (1)
Questions 43 (3)
Batteries 46 (51)
Storage Batteries 46 (1)
Types of Batteries 47 (1)
Safety Precautions 47 (1)
Battery Construction 47 (4)
Battery Operation 51 (4)
Maintenance-Free Batteries 55 (1)
Specific Gravity versus Voltage 56 (1)
Battery Selection 56 (1)
Battery Ratings 57 (2)
Series and Parallel Hookup of Batteries 59 (2)
Battery Terminal Post Dimensions 61 (1)
Battery Cables 61 (2)
Battery-Mounting Recommendations for 63 (3)
Heavy-Duty Trucks
Safety Precautions Prior to Servicing 66 (1)
Hydrometers 66 (2)
Battery Temperature versus Cranking Power 68 (1)
Battery Maintenance in the Vehicle 69 (1)
Battery Troubleshooting 70 (6)
Summary of Battery Tests 76 (1)
Cold Weather Battery Cranking Power 76 (4)
Winter Preventive Maintenance 80 (1)
Cold Weather Boost Starting Precautions 81 (1)
Emergency Jump Starting 81 (3)
Activating Dry Charged Batteries 84 (1)
Battery Storage 85 (1)
Charging of Batteries 86 (5)
Battery Ground Paths 91 (2)
Electrical Load Determination 93 (1)
Questions 94 (3)
Electrical Troubleshooting 97 (19)
Introduction 97 (1)
How to Find an Electrical Problem 98 (1)
Circuit Review 99 (2)
Circuit Protective Devices 101 (1)
Review: Basic Circuit Diagnosis 101 (1)
Basic Diagnostic Tools 102 (11)
Questions 113 (3)
Cab, Chassis, and Trailer Wiring Systems 116 (52)
Introduction 116 (2)
Recommended Wiring Practices 118 (2)
Cab Harness Routings 120 (1)
Circuit Protection 120 (12)
Reading a Wiring Diagram 132 (7)
Chassis Wiring Repair 139 (1)
Wire and Cable Shrink Tubing 140 (2)
Wire Selection 142 (2)
Cable Ties 144 (1)
Types of Connectors 145 (8)
Fault Tracing 153 (2)
Electrical Bulkhead Connectors 155 (1)
Semi-trailer Lighting Systems 156 (6)
Truck/Trailer Lighting Diagnostic Test 162 (3)
Equipment
Scanner Light Tester 165 (1)
Questions 166 (2)
Truck and Trailer Lighting Systems 168 (38)
Introduction 168 (2)
Light Bulb Identification 170 (6)
Heavy-Duty Headlamps and Circuits 176 (8)
Headlight Adjustment 184 (3)
Headlight Troubleshooting and Replacement 187 (3)
Taillamp Assemblies 190 (8)
Clearance and Marker Lamps 198 (1)
Backup Lamps 198 (2)
Truck-Tractor Hookup Lamps 200 (1)
Dome Lamps 200 (1)
Heated and Lighted Mirrors 200 (2)
Questions 202 (4)
Instruments and Gauges 206 (27)
Basic Gauge Operation 206 (3)
Water and Oil Temperature Gauges 209 (1)
Oil Pressure Gauge 210 (1)
Voltmeter Gauge 211 (1)
Ammeter Gauge 211 (2)
Fuel Level Gauge 213 (1)
Electric Tachometers 213 (1)
Programmable Electronic Speedometers 213 (4)
Instrument Panels 217 (4)
Engine Protection Systems 221 (7)
Low-Air-Pressure Warning System 228 (1)
Electrohydraulic Brake Booster Pump 229 (1)
Questions 230 (3)
Alternator Charging Systems 233 (89)
General Information 233 (1)
Basic Electrical System Loads 234 (1)
Basic Alternator Operation 235 (3)
What Is Alternating Current? 238 (1)
Single-Phase Alternating Current 239 (1)
Three-Phase Stator Winding 240 (3)
Stator Wiring Designs 243 (1)
Rectification of AC Voltage 243 (1)
Types of Alternators 244 (1)
Delco-Remy Alternators 245 (15)
Alternator Precautions 260 (1)
Alternator Test Equipment 261 (2)
Delco Generator Output Tests 263 (9)
Leece-Neville Alternators 272 (9)
Multi-Battery Hookup Charging Problems 281 (5)
Nippondenso Alternators 286 (2)
Ford Motorcraft Alternators 288 (4)
Prestolite/Motorola Alternators 292 (3)
Alternator Disassembly and Repair 295 (15)
Alternator Drive Belts 310 (4)
Alternator Selection Process 314 (4)
Questions 318 (4)
Electric Starting Motors 322 (69)
Introduction 322 (1)
Basic Motor Operation 323 (2)
Starter Designs: Main Components 325 (3)
Starter Motor Operation 328 (8)
Coaxial Starter Motors 336 (1)
Gear Reduction Starter Motors 336 (1)
Heavy-Duty Truck Starter Motor Relays: 337 (5)
Switches and Solenoids
Series-Parallel Starter Circuits 342 (8)
Transformer Rectifier Circuits 350 (1)
Multivoltage Management System 351 (1)
Overcrank Protection Devices 351 (2)
Starter Motor Troubleshooting: On Vehicle 353 (7)
Systematic Starter Motor Checks: On Vehicle 360 (4)
Starter Motor Checks: Off Vehicle 364 (4)
Starter Motor Overhaul 368 (13)
Starter Motor Reassembly 381 (5)
Questions 386 (5)
Truck Electrical Accessories 391 (50)
Introduction 391 (1)
Electric Horn 391 (3)
Electric Windshield Wipers 394 (8)
Jacobs Engine Brake 402 (7)
Caterpillar Brakesaver 409 (1)
Power Windows 410 (1)
Electronic Cruise Control 410 (3)
Thermatic Engine Fans 413 (3)
Radio 416 (7)
Basic Cab Heater System 423 (1)
Basic Air Conditioning System 423 (6)
Anti-Brake-Skid Systems 429 (2)
Commercial Vehicle ABS Systems 431 (3)
Bosch/Wabco ABS System 434 (1)
Two-Speed-Axle Electric Shift System 435 (2)
Questions 437 (4)
Engine/Vehicle Sensors and Computers 441 (51)
Introduction 441 (3)
Computer Considerations 444 (1)
Diesel Engine Electronic Fuel Injection 444 (2)
Controls
Engine Control Computers 446 (2)
Basic History and Terminology of 448 (1)
Minicomputers
Analog-versus Digital-Type Computers 449 (1)
Computer Layout and Arrangement 450 (2)
Computer Memory 452 (1)
Input/Output Interface System 453 (3)
Computer Devices 456 (1)
Computer Programming 456 (5)
Logic Circuits 461 (5)
Synchronous Clock Counter 466 (1)
Analog-to-Digital Converter 467 (3)
Digital-to-Analog Converter 470 (1)
Data and Address Buses 471 (1)
Microcomputer Control 472 (1)
CPU (Central Processing Unit) 473 (2)
Data/Instruction Processing 475 (1)
Sensors 476 (7)
Diesel Truck Computer Systems 483 (1)
Electronics Interface 484 (1)
Computer Access and Troubleshooting 485 (3)
Questions 488 (4)
Glossary of Automotive and Truck Electronic 492 (10)
Terms
Index 502

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