Automatic transmissions breathers, 160 cold startup, 156 external line and oil cooler inspection, 160 governor filters, 158–159 hydraulic fluid recommendations, 156 inspection, 154 oil changing, 156–157 checking, 154–156 contamination of, 159 coolant leakage, 159–160 level readings, 154–155 metal particles, 159 oil filters, 156–157 oil pans, 157–158 Axial wheel runout, 167, 169–170 Axle extenders, 330f Axle gear lube viscosity, 126t Axles, 126–128, 362–363 B B lock mechanisms, 291f Ball joint separators, 34 Ball joints, 230–231, 239 Banjo housings, 127–128 Barn style doors, 323 Barrels, tank, 341, 342f Batteries cell voltage, 257 chargers for, 310f charging, 263–265 inspection, 360–361 installation, 265–266 jump starting, 265 maintenance of, 259 ratings, 258–259 removal, 265–266 safety, 256 storage, 259 temperature, 263t testing, 260–263 types of, 257–258 Battery Council International (BCI) dimensional group number, 258–259 Bearing pullers, 32f Bearing settings, wheel-end, 180f Bell cranks, 153f Bell/clutch housing mounting flange inspection, 136 Belts air-conditioning system, 220 alternator, 267–268 cooling fan, 105 drive, 120, 220, 311–312, 360 seat, 216, 357 Bench grinders, 36 Bias ply tires, 180 Bits drill, 52–53 TORX, 26–27 Blades cooling fan, 104–105 hacksaw, 23 Bleeder screws, 309f Blowguns, 35 Body maintenance, 219 Bolster plates, 278 Bolts classes, 50f elasticity of, 49–50 grades, 48 mounting, 315 U-bolts, 243–244, 332 upper coupler, 302 Boots, 3 Bore measurements, 41 Bosch charging pumps, 117f Bottoming taps, 30 Box-end wrenches, 25 Brackets, 332 Brake adjustment limits, 207 Brake drums, 193–194, 209, 332 Brake fade, 193 Brake fluid, 190–191 Brake hoses, 195, 209 Brake lines, 195 Brake linings/pads, 195–197, 204, 207–208 Braking systems. See also air brake systems; hydraulic brake systems defective brakes, 210 OOS criteria for, 207–210 overview, 189–190 trailers, 332, 335 vacuum, 197–198 Brazier head rivets, 56 Breathers, 127, 159f, 160 Buck riveting, 56–57 Bucking bars, 56 Buckle-release mechanisms, 65 Buffing wheels, 36 Bump caps, 4 Bunk heater and air conditioning systems, 103 Bunk restraints, 357 Bushings, 243, 247 Bypass circuits, 100–101 Bypass oil filters, 113 C C inspection, 340–344 C-4 fluids, 156 Cab over engine (CEO) remote shift linkage inspection, 136–137 Cabinets, safety, 6 Cabs. See also chassis/cab service and inspection air suspension systems, 217–218 interior inspection, 355–356, 364 mounting latches, 217 PMI, 65–67 walk around inspection, 357, 364–365 Calibration, micrometer, 39 Camber, 237–238 Canister type oil filters, 114 Caps, bump, 4 Carbon dioxide extinguishers, 7 Carbon drill bits, 52 Carbon monoxide (CO), 6 Carrier refrigeration units, 310 Carrying, safe, 4 Cartridge type oil filters, 114 Cast spoke wheels, 166–170 Caster, 238 Caterpillar transfer pumps, 117f CCA (cold cranking amps) rating, 258, 262 C-clamp fixtures, 294 Center punches, 24 Center support bearings, 131–132 Centering pins, height control valve, 249 Centrifuges, water separator, 116 CEO (cab over engine) remote shift linkage inspection, 136–137 Certification plates, 325–326 Chain hoists, 15 Chalmers solid rubber suspension system, 243 Channel Locks, 28 Charging pumps, 114, 117f Charging systems, 266–268 Chassis/cab service and inspection air conditioning, 219–220 air suspension systems, 217–218 body maintenance, 219 controls, 216 driver seats, 218–219 hardware inspection and maintenance, 217 instruments, 216 onboard safety equipment, 216 overview, 215–216 PMI, 361–362, 366 refrigerant leak detection, 221–223 Chemical sealing materials, 58 Chisels, 24–25, 34, 55 Clevis adjustment, 153f, 204f Click torque wrenches, 42 Climate control systems, 101–103, 216, 219–220, 356 Closed thermostats, 102f Clothing, personal safety, 3 Clutch brake squeeze, 146, 147f, 148 Clutch brakes, 142, 150–152, 154, 356 Clutch control adjustment arms, 143f Clutch linkages, 142–144, 152–154, 361 Clutch shaft yoke bushing inspection, 136 Clutches adjustment mechanisms, 139–140 clutch brakes, 142, 150–152, 154, 356 linkages, 142–144, 152–154 maintenance of adjustment, 145–146 internal adjustment, 147, 150–151 Kwik-adjustment mechanism, 149 378 Index
lockstrap mechanism, 147–149 lubrication, 144–145 wear compensator, 149–150 overview, 138–139 release mechanisms, 140–142 CO (carbon monoxide), 6 Coalesced water, 116 Coats, shop, 3f Cold cranking amps (CCA) rating, 258, 262 Cold temperatures, 134, 156 Color code, thread locking compound, 55 Combination wrenches, 25 Combustible material fires, 7 Commercial battery load testers, 261–263 Commercial vehicle operator’s registration (CVOR), 216 Commercial Vehicle Safety Alliance (CVSA), 64, 69, 70f–75f Communication, driver/technician, 62 Compressed air, 35 Compressor oil level, 314–315 Computerized record keeping, 77–79 Condensers, 315, 359 Cones, stud-piloted mounting system, 170, 172–173 ConMet ASF Simplex fifth wheels, 286 ConMet PreSet hubs, 175, 179 ConMet Simplex 400 fifth wheels, 284–286 Conspicuity tape, 330, 340 Control doors, 101 Conventional batteries, 257 Convoluted air springs, 246, 248–249 Coolant additive testing, 360 advantages of, 88–89 extended life, 90–91 flushing, 313 glycol-based, 89 high silicate, 90–91 leakage of, 159–160 mixing, 89–90 recyclers, 93 refractometer operation, 91 replacement of, 312–313 scaling, 91–92 testing, 91–93 Coolant filters, 93–94 Coolant hoses, 106, 359 Coolant recovery systems, 359–360 Coolant recyclers, 93, 94f Coolant valves, 103 Cooling fans, 104–107, 120–121, 359 Cooling systems. See also coolant components of bunk heater and air conditioning, 103 cooling fans, 104–107 heater control valves, 103 heater cores, 101–102 radiators, 94–98 shutters, 103–104 thermostats, 100–101 water pumps, 98–100 coolant filters, 93–94 coolant replacement, 312–313 flushing, 313 leaks, 106–107 management of, 107 overview, 87–88 PMI, 359 pressure testing kits, 98–99, 106–108 Cores heater, 101–102 radiator, 95 Corrosion inhibitors, 88 Corrosive materials, 7 Counterbalancing springs, 324 Coupling systems. See also fifth wheels; kingpins couplers, 298–301 drawbars, 299–301 lubrication, 291–292 OOS criteria for, 301–303 overview, 277–278 pintle hooks, 298–301 Coveralls, 3f Cracked hangers, 242f Cracked rims, 168 Cranes, 15 Cross-members, floor, 321, 325, 331 Cruise control, 363 Cummins systems, 114–115 Current flow, 263, 266 Current-draw tests, 268f Cutters, exhaust pipe, 34 CVOR (commercial vehicle operator’s registration), 216 CVSA (Commercial Vehicle Safety Alliance), 64, 69, 70f–75f D Daily Reminder screen, Dossier program, 82f Dampening, 247 Damper doors, 315 Dana Spicer Unitized Hub System (UHS), 179 DD-3 brake chamber data, 210 Deadlining vehicles, 68–69 Deburring, 24 Decals, inspection, 76 Decimal rulers, 36 Deep cycling, 257 Deep-well sockets, 27, 28f Defrost systems, 313–314 Demountable rim systems inspection, 167–168 installation, 168–169 overview, 166–167 runout, 169–170 Department of Transportation (DOT), 62–63 De-scaling agents, 91 Desiccants, 200–201 Diagonal cutting pliers, 29 Dial calipers, 38 Dial indicator torque wrenches, 42 Dial indicators, 235 Die stocks, 31 Dies, 31 Diesel powered tractor PMI air brake systems, 356, 364 cabs, 355–357, 364–365 chassis, 361–362, 366 electrical systems, 359–361, 365–366 engine oil service, 362–363, 367 engines, 359–361, 365–366 lubrication, 362–363, 367 road testing, 363, 367 tires, 358–359, 365 undercarriages, 361–362, 366 wheels, 358–359, 365 Differential carrier lubricants, 126 Differential carrier pinion angles, 127–128 Digital measuring tools, 41 Digital multimeters (DMMs), 202, 269 Dipsticks, 113, 155f Disc brakes lining/pad thickness, 196 rotors, 194–195, 204, 209 Disc wheels hub-piloted wheels, 171, 173–175 inspection, 175–176 mounting torque for, 176 overview, 166 stud-piloted wheels, 170, 172–173 wide-base wheels, 171–172 Discharge systems, dry bulk tank, 349, 351 Disposal, hazardous material, 9–14 Distilled water, 257 DMMs (digital multimeters), 202, 269 Dog tracking, 328 Door glass, 217 Doors control, 101 damper, 315 van, 323–324, 331, 334 Dossier program, 79–83 DOT (Department of Transportation), 62–63 Double check valves, 203 Double flare brake lines, 196f Double shear bottom side rail design, 322, 323f Drag links, 229, 239 Drain cocks, 199f Drain hoses, 315 Drain plugs drive axle, 127 oil, 308f Drain valves, air tank, 199f Draining air tanks, 198–199 lubricant, 113, 127 oil, 136 Drawbars, 299–301, 303 Drill bits, 52–53 Index 379
Drills, 33f, 34, 52–53 Drive axles, 126–128, 362–363 Drive belts, 120, 220, 311–312, 360 Drive trains. See also automatic transmissions; clutches; driveshafts drive axles, 126–128 overview, 125–126 PMI, 136–138 standard transmissions, 135–136 wheel bearing lubrication, 128–129 Driver’s inspection, 62–64 Driver’s seats, 217–219 Driveshafts bearing assemblies, 131 center support bearings, 131–132 construction of, 129 inspection, 132–133 lubrication, 133–135 mounting hardware, 131 overview, 129–130 universal joints, 130–131 Dropoff rates, 200 Drum brakes, 196, 204 Dry bulk cargo tanks, 349–352 Dry chemical extinguishers, 7 Dry positive air filters, 118–119, 311 Dual mating, 333, 358 Dual wheels, 181–182, 341f Dump trailers, 326–327 Duplex wheels, 171 Dust caps, 345 E E-250 lubricant, 135 E-500 lubricant, 135 Ear muffs, 3f Ear plugs, 3 Earphone-type protectors, 3 EG (ethylene glycol), 88–89 EGR (exhaust-gas-recirculation) engines, 88 Elasticity, bolt, 49–50 ELC (extended life coolants), 90–91 Electric fuel pumps, 310 Electrical drills, 33f Electrical fires, 7 Electrical systems. See also batteries charging systems, 266–268 diesel powered tractor PMI, 359–361, 365–366 liftgates maintenance of, 271–272 safety, 269–271 troubleshooting, 272–274 overview, 255–256 starters, 268–269 Electrodes, zinc oxide, 94 Electro-hydraulic assist service brakes, 197 Electrolytes, 256–257, 264 Electronic leak detectors, 222 Electronic rust protection, 219 Elevating fifth wheels, 280 Emergency brake systems, 203–204 Emergency phone numbers, 6 Emulsified water, 115–116 Endplay, 178 Engine compartments, 64–65, 120–121 Engine flywheels, 138–139 Engine lubrication system, 308–309 Engine mounting, 120, 361 Engines air filters, 118–119 compartment inspection, 120–121 diesel powered tractor PMI, 359–361, 365–366 fuel filters, 113–115 hand primer pumps, 117–118 harmonic balancers, 119–120 oil, 112–113, 362–363, 367 oil filters, 113 OOS criteria for, 118, 121 overview, 111–112 water separators, 115–117 Environmental Protection Agency (EPA) certification, 223 EP (extreme pressure) grease, 133 Ethylene glycol (EG), 88–89 Evaporators, 315 Exhaust leakage, 121 Exhaust pipe cutters, 34 Exhaust stacks, 357 Exhaust systems, 121, 360 Exhaust-gas-recirculation (EGR) engines, 88 Expansion tanks, coolant, 97 Exploring Units screen, Dossier program, 82f Extended life coolants (ELC), 90–91 External TORX bit sockets, 27 External valves, 342–343 External visual (V) inspection, 344 Extreme pressure (EP) grease, 133 Eye protection, 2, 22–24, 29–30, 33 F Face shields, 2f Fan rings, 120–121 Fan shrouds, 95, 106, 120–121 Fans, 104–107, 120–121, 359 Fanstats, 105 Fasteners adhesives, 58 chemical sealing materials, 58 classes of, 48 frame, 48–49 grades of, 48 inspection, 136 overview, 47–48 rail, 331 replacement of, 51–52 rivets, 56–58 thread repair, 53–56 tightening, 49–52 twist drills, 52–53 wheel, 176 Federal Motor Carrier Safety Regulations manual, 63, 69 Federal Motor Vehicle Safety Standard (FMVSS) vehicle record requirements, 14–15 Feeler gauges, 42 Fenders, 341f Fiberglass engine cooling fans, 104 Fibreglass Reinforced Plastics (FRP) plywood trailers, 322–323 15W-40 engine oil, 112 Fifth wheel plates, 302 Fifth wheels capacity, 281 ConMet ASF Simplex, 286 ConMet Simplex 400, 284–286 Fontain No-Slack II, 286–287, 288f fully oscillating and compensating, 279–280 height, 281–282 Holland Hitch A-type mechanism, 282–283, 290–291 Holland Hitch B-type mechanism, 283–284, 291 location, 282 maintenance, 287–290 OOS criteria for, 301–302 operation, 282 overview, 278–279 PMI, 357 semi-oscillating, 279 service tools, 295f sliding, 279, 290f specialty, 280–281 50 engine oil, 112 Files, 29–30 Filler necks, radiator, 95, 96f Filters air, 118–119, 137, 310–311 fuel, 113–115, 308–309 governor, 158–159 HVAC, 220 oil, 113, 156–157, 308 Final back-off, 177t Fire extinguishers, 7, 8t Fire safety, 6–7 Firefighting equipment, 6–7 5W-30 engine oil, 112 5W-40 engine oil, 112 5W-50 engine oil, 112 Flame-type leak detectors, 221 Flammable liquids, 6 Flammable materials, 7 Flanges, 136, 345 Flares, 216 Flaring tools, 24f FleetMaster locking mechanism, 282 Flex bar torque wrenches, 42 Flexibility, air tool, 32 Floor cross-members, 321 Floors, 321, 324–325, 334 Fluid-type leak detectors, 221 380 Index
Flush head rivets, 56 FMVSS (Federal Motor Vehicle Safety Standard) vehicle record requirements, 14–15 Foam extinguishers, 7 Foaming suppression, 88–89 Fontain No-Slack II fifth wheels, 286–287, 288f Footprints, tire, 180 Footwear, 2–3 40 engine oil, 112 Frame fasteners, 48–49 Frame machines, 15 Free pedal, 145–146 Free play, 148 Free state water, 115–116 Free stroke travel (freestroke), 205–206 Freeze points, battery, 261 Friction discs, 138–139 Front axle beams, 239 Front brakes, 208–209, 361 Front suspension inspection, 65–66 Front wheel bearings, 361 FRP (Fibreglass Reinforced Plastics) plywood trailers, 322–323 Fuel filters, 113–115, 308–309 Fuel lines, 121 Fuel pump governors, 360 Fuel systems, 118, 309–310 Fuel tank area, 66–67, 357 Fuel transfer pumps, 117f Full-round end yokes, 131 Full-service haulers, 14f Fully oscillating and compensating fifth wheels, 279–280 Fusible plugs, 345 G Gasification, electrolyte, 257–258 Gaskets, 115, 136 Gasket-type sealing compounds, 158 Gassing, electrolyte, 264 Gauges kingpin, 293–294 screw pitch, 42 temperature, 342f thickness, 42 threaded pitch, 54f GAWR (gross axle weight rating), 282 Gear and bearing pullers, 31, 32f Gearing arrangements, air spring suspensions, 244f Gearshift lever inspection, 137 Gladhands, 202, 331–332, 357 Glass, door, 217 Glasses, safety, 2 Glazing, drive belt, 220 Gloves, 3, 33, 36 Glow plugs, 312 Glycol-based antifreeze, 89 Goggles, 2f, 4, 5f Governor cutout testing, 199–200 Governor filters, 158–159 Grab handles, 357 Grease, transmission, 158 Green triangles, 3 Grinding wheels, 36 Gross axle weight rating (GAWR), 282 Gross vehicle weight rating (GVWR), 325 H Hacksaws, 23 Hair, safety issues, 4 Half-round end yokes, 131, 134 Hammers, 21–23 Hand primer pumps, 117–118, 309 Hand protection, 3 Hand taps, 30–31 Hand throttles, 356 Handles fifth wheel operating, 302 grab, 357 hammer, 22 screwdriver, 20f wrench, 28 Hand-threading dies, 31 Hanger bearings, 131–133, 135 Hangers, 242f, 357 Harmonic balancers, 119–120 Haulers, full-service, 14f Hazardous materials disposal of, 9–14 employee/employer obligations, 9 handling of, 9–14 laws regulating, 7–9 personal protection from, 9 Headed wheel studs, 172 Hearing protection, 3, 33 Heat transfer rates, 95 Heater control valves, 103 Heater cores, 101–102 Heater hose lines, 103f Heating, ventilating, and air conditioning (HVAC) systems, 103, 215, 219–220 Heat-sensing elements, thermostat, 100 Heavy-duty oil pans, 157 Height control valves, 332 Helical coil inserts, 53 Helmets, welding, 4, 5f Hex head fasteners, 48 Hex nuts, 48, 49f Hex points, 25 High flotation wheels, 171 High hitches, 296 High silicate antifreeze, 90–91 High-pressure washers, 95 High-speed drill bits, 52 Hinged doors, 323–324 Hoists, 15 Holders, 357 Holland Hitch Company adjustment of locking mechanisms, 289f as-needed lubrication guide, 288f A-type mechanisms, 282–283, 290–291 B-type mechanisms, 283–284, 285f, 291 fifth wheel inspection, 289f overview, 278 pintle hook/coupler maintenance, 301 service tools, 295f Holland Kampensator, 280f Holland Simplex fifth wheels, 286, 287f Hood cables, 217 Horns, 216, 356 Horseplay, 4 Hose permeation, 221 Hoses brake, 195, 209 coolant, 106, 359 radiator, 95 Housing breathers, 127 Hub odometers, 333 Hubcaps, 361 Hub-piloted wheels, 171, 173–175 Hubs, 176–177, 332–333, 335 Huck fasteners, 49 HVAC (heating, ventilating, and air conditioning) systems, 103, 215, 219–220 Hydraulic brake systems bleeding, 191–192 defective brakes, 197 drums, 193–194 fluid, 190–191 lines and hoses, 195 linings/pads, 195–196 master cylinders, 192–193 OOS criteria for, 197 parking brake testing, 196 rotors, 194–195 service brakes, 196–197 Hydraulic clutch linkages, 143–144 Hydraulic fluid, 156, 270–271 Hydraulic lift cylinders, dump trailer, 327 Hydraulic presses, 5 Hydraulic pumps, 217 Hydraulic tools, 31 Hydraulically actuated elevating fifth wheels, 281f Hydrometers, 89, 91, 260–261 Hydrostatic pressure test (P) inspection, 344, 348 Hygroscopic fluids, 190 I I (internal visual) inspection, 344 Ignition keys, 216, 355 Impact sockets, 27 Impact wrenches, 27, 34, 51 Impellers, 98 Imperial vernier measurements, 37 Inboard brake drums, 193 Inner cap nuts, 170 Inner wheel ends, 332 Inside micrometers, 41 Index 381
Inspection records, 14 Inspection stickers, 331 Inspection symbols, 344 Interaxle differential draining, 127 Intercooler pipes/hoses, 121 Interference fits, 31 Interior cubes, 324 Interior lights, 334, 356 Internal clutch adjustment, 147, 150–151 Internal heads, 346f Internal valves, 342–343, 347f Internal visual (I) inspection, 344 International Organization for Standardization, 26 J Jacks, 15 Jam nut torque, 179t Jewelry, safety issues, 4 Jounce, 239 Jumbo wheels, 171 Jumper cables, 265 K K (pneumatic pressure test) inspection, 344 Kingpin gauges, 293–294 Kingpins coupling procedures, 294–296 diameter, 293 dimensions, 293 inspection, 233, 331, 361 lower bushing, 236 maintenance of, 230, 293–294 OOS criteria for, 302 overview, 278, 292 servicing tools, 294, 295f settings, 279 squareness and height, 293 testers, 348f trailer axle alignment, 329 uncoupling procedures, 296–298 upper bushing, 234–236 Knives, 23–24 Knuckle pins, 230 Kwik-adjustment mechanisms, 149 L Lading seals, 345 Landing gear, 331, 334, 350 Lash, steering gear, 233 Lateral runout, 194, 333 Laws hazardous materials, 7–9 PMI, 75–76 Lawsuits, 62 Leaf spring suspensions, 240–243 Leak detection, 349 Leakage rates, 200 Leakage testing dry bulk cargo tanks, 351–352 refrigerant, 221–223 reservoir air supply, 200 tank trailer, 346–347 Leveling valves, 249 License plates, 331 Liftgates maintenance of, 271–272 safety, 269–271 switches, 270f troubleshooting, 272–274 Lifting, safe, 4 Lifting points, 15 Lifts, 15 Lights inspection, 216 interior, 334, 356 panel, 216 trailer, 331 warning, 355 Line flares, 195f–196f Lipe clutches, 140f, 142f Liquid fuel systems, 118, 309–310 Liquid-based fires, 7 Litmus tests, 92 Load testing, 261–263, 267f, 269 Lock plates, 139 Lock testers, fifth wheel, 282, 294 Lock washers, 48, 49f, 51 Locking mechanism inspection, 289f, 302, 332 Locking pliers, 29 Lockstraps, 139, 147–149 Logistics tracks, 334 Long stroke chambers, 207, 209–210 Looseness testing, rivet, 321–322 Low pressure warning devices, 203, 209 Low-maintenance batteries, 257–258 Lube pumps, 128 Lubrication air tool, 32–33 cab hardware, 217 change intervals, 137 clutch, 144–145 coupling system, 291–292 diesel powered tractor PMI, 362–363, 367 drive axle, 126–128 driveshaft, 133–135 fastener, 51–52 Holland’s as-needed lubrication guide, 288f steering axle component, 233 trailer PMI, 334, 335–336 Lunettes, 299–301, 303 M Machinist’s rules, 36 Magnetic strainers, 128 Maintenance records, 14 Maintenance software, 77–79 Maintenance-free batteries, 258 Manholes, tank, 340, 346 Manual adjust mechanisms, free travel, 149 Manual drain valves, 199 Manual slack adjusters, 205 Manually adjusted clutches, 139 Master cylinders, 192–193 Material Safety Data Sheet (MSDS), 9, 10f–13f Maximum allowable working pressure (MAWP), 344 Maximum capacity decals, 270f Measuring tools dial calipers, 38 digital, 41 machinist’s rules, 36 micrometers, 38–41 screw pitch gauges, 42 thickness gauges, 42 torque wrenches, 42 vernier calipers, 36–38 Mechanical clutch linkages, 143 Mechanically suspended seats, 218 Metric dial calipers, 38 Metric fasteners, 48 Metric rulers, 36 Metric vernier measurements, 37–38 Metric wrenches, 25 Micrometers (mikes), 38–41 Mineral-based lubricants, 126, 135 Mirrors, 217, 357 Mixing heavy-duty coolant, 89–90 Monthly PM schedules, 76f Mounting bolts, 315 MSDS (Material Safety Data Sheet), 9, 10f–13f Mud flaps, 332, 341f, 357 Multi-grade engine oils, 112 Multileaf shackle springs, 240f Mushroomed heads, 24 N National Highway Traffic Safety Administration (NHTSA), 65, 75–76 National Lubricating Grease Institute (NLGI) classification, 133 Needle bearings, 131 Needlenose pliers, 29 Negative camber, 237 Neutralization, electrolyte, 256 NHTSA (National Highway Traffic Safety Administration), 65, 75–76 NLGI (National Lubricating Grease Institute) classification, 133 Nuts hex, 48, 49f identification of, 49f–50f inner cap, 170 jam, 179t prevailing torque lock, 48, 50f rim lug, 168, 169f steering mechanism, 239 382 Index
O Occupational Safety and Health Administration (OSHA) Right-to-Know Law, 7–8 OEMs (original equipment manufacturers), 63 Ohmeters, 312 Oil air tool, 32–33 automatic transmission changing, 156–157 checking, 154–156 contamination of, 159 coolant leakage, 159–160 level readings, 154–155 metal particles, 159 engine lubrication, 112–113, 308 samples, 362 seepage, brake area, 208 spills, 5 viscosity ratings, 113, 308f Oil bath air filters, 118–119, 310–311 Oil coolers, 160 Oil filler tube seal rings, 155 Oil filters, 113–114, 156–157, 308 Oil leaks, 136 Oil lines, 121 Oil pans, 157–158 Oily rags, 6 Onboard safety equipment, 216, 356 One-way check valves, 203 On/off fan hubs, 105 OOS criteria. See out-of-service criteria Open circuit voltage testing, 261 Open thermostats, 102f Open-end wrenches, 25 Operating handles, 302 Original equipment manufacturers (OEMs), 63 Oscillation fifth wheel, 279–280 suspension, 240 OSHA (Occupational Safety and Health Administration) Right-to-Know Law, 7–8 Outboard brake drums, 193 Out-of-service (OOS) criteria braking system, 197–198, 207–210 coupling system, 301–303 engine, 118, 121 exhaust system, 121 fuel system, 118 overview, 68–69 steering system, 238–239 suspension, 250–251 tires, 185–186 wheel, rim, and hub, 176–177 Output shaft assembly inspection, 137 Output yoke seal inspection, 136 Out-riggers, 341 Outside micrometers, 39–41 Overfill systems, 345 Overfilling, transmission, 136 Overflow tanks, coolant, 96–97 Overheating, electrolyte, 264 Overtensioning, 49 Oxyacetylene goggles, 5f P P (hydrostatic pressure test) inspection, 344, 348 Painting, brake drum, 194 Panel lights, 216 Parking brake systems, 196, 203–204, 209, 356 Parts requisitions, 15 Pedals, 217 Pellets, thermostat, 100 Pencil inspection, 62 Penetrating fluid, 55 Permeation, hose, 221 Personal hygiene, 9 Personal safety equipment, 2–4 Petcocks, radiator, 95 PG (propylene glycol), 88–89 Phillips screwdrivers, 20, 21f, 26 Phone numbers, emergency, 6 Pintle hooks, 298–301, 332, 357 Piping inspection, 344 Pitman arms, 228–229, 239 Pivot brackets, 301 Pivot points, liftgate, 271–272 Placard holders, 340f Placards, 331 Planning, PM program, 62 Pliers, 28–29 Plug taps, 30 Plungers, 292f PMI (preventive maintenance inspection) deadlining vehicles, 68–69 diesel powered tractors with air brakes air brake pneumatic system, 356, 364 cab, 355–357, 364–365 chassis, 361–362, 366 electrical system, 359–361, 365–366 engine, 359–361, 365–366 engine oil service, 362–363, 367 lubrication, 362–363, 367 road testing, 363, 367 tires, 358–359, 365 undercarriage, 361–362, 366 wheels, 358–359, 365 drive train, 136–138 driver’s inspection, 63–64 federal regulations, 75–76 implementing programs, 62–63 OOS criteria, 68–69 overview, 61–62 procedure, 64–68 record-keeping requirements, 76–79 scheduling, 69–75, 138f software, 79–83 trailer brakes, 332, 335 extended interval, 334, 336 exterior, 334 front, 331 hubs, 332–333, 335 interior, 333–334, 335 lubrication, 334, 335–336 overview, 330–331 suspension, 331–332, 334–335 tires, 333, 335 undercarriage, 331–332, 334–335 wheels, 333, 335 Pneumatic pressure test (K) inspection, 344 Pneumatic rivet guns, 56 Pneumatic tools, 31–32 Pneumatically fifth wheels elevating, 281f sliding, 292f Pneumatically suspended seats, 218, 219f Posi-Drive screwdrivers, 21f Positive camber, 237–238 Positive filtration, 113 Post-trip inspection, 63 Power steering. See steering systems Power steering fluid, 360 Power steering pumps, 121 Power take off (PTO), 121, 216 Power tools air chisels, 34–35 air drills, 34 air hammers, 34–35 air ratchets, 34 bench grinders, 36 blowguns, 35 impact wrenches, 34 maintenance of, 32–33 overview, 31–32 presses, 36 safety, 33–34 Preloads, 194 Preset hub assemblies, 179 Presses, 36 Pressure protection valves, 246 Pressure regulators, 246 Pressure relief devices, 342f, 351 Pressure testing cooling systems, 106–108 radiator caps, 99 tank trailers, 348 Pressurization, fuel tank, 117 Pre-trip inspection, 63–64 Prevailing torque lock nuts, 48, 50f Preventive maintenance inspection. See PMI Primary reservoirs, 203 Priming, oil filter, 113, 115 Probes, TDS, 92 Product lines, tank trailer, 342f Propylene glycol (PG), 88–89 PTO (power take off ), 121, 216 Pulleys, cooling fan, 105 Pull-type clutches, 141–142, 146–147 Pump tank extinguishers, 7 Punches, 24–25, 35 Index 383
Purge valve housing assemblies, 202 Pusher-type fans, 104 Pushrod travel (applied stroke), 207 Push-type clutches, 140–141, 146 R Radial play, 132 Radial tires, 180 Radiator caps, 96–98, 360 Radiator fans, 104–107, 120–121, 359 Radiator mountings, 120 Radiators, 94–98, 359 Ram air, 94 Ratchets, 27, 51 RCRA (Resource Conservation and Recovery Act), 9 Reactive materials, 7 Rear doors, 331 Rear impact guards, 327–328 Rebound, 239 Rebuilding master cylinders, 193 water pumps, 100 Records PMI, 76–79 VIN, 14–15 work orders, 15 Recovery, refrigerant, 223 Reflective tape, 330 Reflectors, trailer, 331 Refractometers, 89, 91, 92–93f, 260, 262 Refrigerant leak detection, 221–223 testing level, 314 Refrigeration maintenance air filter, 310–311 bleeding fuel system, 309–310 compressor oil level, 314–315 defrost system, 313–314 drive belts, 311–312 engine cooling system, 312–313 engine lubrication system, 308–309 glow plugs, 312 overview, 307–308 pre-trip, 314 structural maintenance, 315 testing refrigerant level, 314 Refueling, tank, 118 Registration holders, 331 Regulators, 121 Release bearings, 140, 144–145, 150–151 Release travel, 147 Remote closure devices, 345 Repair Order screen, Dossier program, 81f Repair orders, 15, 62 Reserve capacity rating, 258 Reservoir air supply leakage testing, 200 Resource Conservation and Recovery Act (RCRA), 9 Restricted service designation, 69 Retainer springs, rivet gun, 56 Reversible sleeve air springs, 246 Ride height control valves, 245–246, 249–250 Right-to-Know Law, 8–9 Rigid fifth wheels, 281 Rim clamps, 169 Rim cracks, 176 Rim lug nuts, 168, 169f Rim studs, 168 Rims, 176–177 Rivet guns, 56 Rivet looseness testing, 321–322 Rivet sets, 56 Rivets, 56–58 Road speed governors, 363 Road testing, 67–68, 363, 367 Rolling lobe pistons, 248 Roll-up van doors, 323–324 Roof bows, 334 Rotochamber data, 210 Rubber bushing splitters, 35 Rubber compound hoses, 106 Runout axial, 167, 169–170 lateral rotor, 194, 333 Rust inhibitors, 219 S Sacrificial anodes, 219 SAE (Society of Automotive Engineers) viscosity grades, 112 Safety air brake systems, 198 air tool, 32 batteries, 256 carrying, 4 chassis/cab, 216 fire safety, 6–7 hazardous materials employee/employer obligations, 9 handling of, 9–14 laws regulating, 7–9 personal protection from, 9 hoists, 15 liftgates, 269–271 lifting, 4 lifts, 15 overview, 1 personal safety equipment, 2–4 power tools, 33–34 records, 14–15 tank trailer, 340, 348–349 tools, 5, 21–25, 28–30 warnings, 4–5 work area, 5–6 Safety cabinets, 6 Safety chains, 299–300 Safety devices, 303 Safety equipment, onboard, 216, 356 Safety glasses, 2 Safety precaution decals, 270f Sand shoes, 296 Saws, 23–24 Scaling, 91–92, 313 S-CAMC foundation brakes, 205–206 SCAs (supplemental coolant additives), 88, 92–93 Screw extractors, 55 Screw pitch gauges, 42 Screwdrivers, 20–21 Scrubbing, tire, 184–185 Scuff liners, 321 Scuffing, 182 Seal failure, water pump, 98 Sealants, 58 Sealed release bearings, 144 Sealing, door, 334 Seat belts, 216, 357 Seats, driver’s, 217–219, 357 Secondary reservoirs, 203 Secure TORX bit sockets, 27 Self-adjusting clutches, 139–140, 150 Semi-absorbed water, 115–116 Semi-oscillating fifth wheels, 279 Service brakes, 196–197, 363 Service records, 14 Service tools, fifth wheel, 295f Servicing water separators, 116–117 Seven-pin connectors, 357 Seven-pin receptacles, 331 SG (specific gravity), 260–261 Shackle springs, multileaf, 240f Sheeting, 334 Shell reinforcements, 347f Shields, face, 2f Shift tower assembly inspection, 137 Shifting performance, 136 Shock absorber bushings, 247 Shock absorber chisels, 34 Shock absorbers, 217–218, 247–248 Shoes, 3 Shop coats, 3f Shop safety. See safety Shrink fits, 31 Shutoff valves, coolant filter, 94 Shutters, 103–104 Shutterstats, 103, 104f Side doors, 331 Sidecutters, 29 Sidewalls, tire, 181f, 358 Sight glasses, oil level, 314, 315f Silicone hoses, 106 Single shear construction design, 322 Single-reduction carriers, 245f Skully systems, 345 Slack adjusters, 205, 334 Sleeper climate control systems, 103 Slide release plunger position, 292f Slide rings, 176 Sliders, 302 Sliding fifth wheels, 279 Slip joints, 129–130 Slip splines, 129–130, 133–134 Slipped wheels, 358–359 384 Index
Slotted screwdrivers, 20–21 Smoke testing, 322 Smoking, 4 Snubbing action, 300–301 Soapsuds solution, 221 Society of Automotive Engineers (SAE) viscosity grades, 112 Socket joints, 239 Socket wrenches, 27–28 Soda-acid extinguishers, 7 Soft-face hammers, 21–22 Software, PMI, 79–83 Solid rubber spring suspensions, 243 Solid square hex dies, 31 Solid-mounted seats, 218, 219f Solvents, 6 Sonic testers, 347 Sound-indicating torque wrenches, 42 Space heaters, 6 Spacer bands, 166, 167f, 169 Spare tire carriers, 332 Specialty fifth wheels, 280–281 Specialty screwdrivers, 20–21 Specialty tools, 30–31 Specific gravity (SG), 260–261 Spiders, 130 Spills, hazardous waste, 14 Spin-on fuel filters, 114–115, 309f Spitter valves, 199 Splash goggles, 2f Splitters, rubber bushing, 35 Spoke wheels, 166–170, 176 Spontaneous combustion, 6 Spring assembly, 250–251 Spring brake chambers, 208 Spring brake inversion valve, 203 Spring ends, 241f Spring packs, 240, 241f Springs. See suspension systems Squares, tire, 182, 358 SRS (supplemental restraint systems), 216 Stand pipes, 131 Standard brake chambers, 207 Standard Fleet Management Edition, Dossier, 80 Standard screwdrivers, 20 Standard stroke clamp type brake chambers, 209 Standard transmissions, 135–136 Standard wrenches, 25 Starter amp draw testing, 268 Starters, 268–269, 355, 361 Steel engine cooling fans, 104 Steel-face hammers, 21, 22f Steering axles, 231f, 232–234 Steering box mountings, 361 Steering columns, 228, 229f, 239 Steering control arms, 229–230 Steering gears, 121, 228, 229–230f, 239 Steering knuckle thrust bearings, 233 Steering knuckles, 230, 231f, 234–236 Steering shafts, 361 Steering systems components of, 228–232 geometry, 237–238 OOS criteria for, 238–239 overview, 227–228 steering axle inspection, 232–234 steering knuckle inspection, 234–236 tie-rod inspection, 236–237 wheel bearing inspection, 237 Steering wheels, 228, 238, 356 Steps, 357 Storage combustible materials, 6 tool, 5 Straight grade engine oils, 112 Straight knuckle pins, 230, 232f Straightedges, 182 Strainers, magnetic, 128 Stud holes, 176 Stud removers, 55 Stud-piloted wheels, 170, 172–173 Studs, disc wheel, 175 Suction-type fans, 104 Super single wheels, 171 Supplemental coolant additives (SCAs), 88, 92–93 Supplemental restraint systems (SRS), 216 Supply reservoirs, 198 Suspension systems air spring, 244–250 fittings, 334 inspection, 239–243 leaf spring, 240–243 OOS criteria for, 250–251 solid rubber spring, 243 trailer PMI, 331–332, 334–335 U-bolts, 243–244 Sway bars, 251 Swing style van doors, 323–324 Synthetic lubricants, 126, 135–136 T T (thickness test) inspection, 344, 347 Tandem slides, 332 Tank barrels, 341, 342f Tank heads, 347f Tank trailers C inspection, 340–344 dry bulk cargo tanks, 349–352 external visual inspection, 344–346 internal visual inspection, 346 leakage testing, 346–347 overview, 339–340 pressure test inspection, 348 safety, 340, 348–349 thickness testing, 347 upper coupler inspection, 347–348 Tape measures, 182 Tapered knuckle pins, 230, 232f Tapered punches, 24, 35 Tapered taps, 30 Taps, 30–31 TDS (total dissolved solids), 92 Technical and Maintenance Council (TMC), 69, 177–179 Temperature gauges, 342f 10S-30 engine oil, 112 10W engine oil, 112 10W-40 engine oil, 112 Tension, fan belt, 105 Thermatic viscous drive fan hubs, 105–106 Thermo King refrigeration units, 309f Thermo-modulated fans, 105–106 Thermostats, 100–101 Thickness gauges, 42 Thickness test (T) inspection, 344, 347 30 engine oil, 112 Thread chasers, 53 Thread locking compound, 55–56 Thread repair, 53–56 Threaded pitch gauges, 54f Threading tools, 53 Throats, fifth wheel, 278 Throttle linkages, fuel pump, 360 Throwout bearings, 140 Tie downs, 334 Tie-rod assemblies, 231–232 Tie-rod ends, 233 Tie-rods inspection, 236–237, 239 tools for, 34 Tilting, cab, 4, 5f TIR (total indicated runout), 194–195 Tire pressure, 182–183 Tire squares, 182 Tire valve caps, 183, 333, 358 Tires dual mating, 181–182 inspection for all tires returning to service, 183–184 for suspected underinflated or overloaded, 183 maintenance of, 182–183 OOS criteria for, 185–186 PMI, 358–359, 365 sizes, 180–181 straightedges, 182 tape measures, 182 trailer PMI, 333, 335 tread depth, 183, 333, 358 wear conditions and causes, 184–185 TMC (Technical and Maintenance Council), 69, 177–179 Toe, 237 Tongues, 303 Tools chisels, 24–25 files, 29–30 hammers, 21–23 knives, 23–24 measuring, 36–42 overview, 19–20 Index 385
Tools (continued) pliers, 28–29 power, 31–36 punches, 24–25 safety, 5 saws, 23–24 screwdrivers, 20–21 specialty, 30–31 tubing, 24 wrenches, 25–28 Torque rods, 251 Torque wrenches, 42 Torque-to-yield (TTY) bolts, 51 TORX screwdrivers, 21 TORX wrenches, 26–27 Total dissolved solids (TDS), 92 Total indicated runout (TIR), 194–195 Total pedal travel, 153f Towed vehicle weight (TVW), 281 Toxic materials, 7 Tracking component assembly, 251 Tractor area inspection, 66–67 Tractor protection systems, 203, 209 Trailer breakaway, 208 Trailer certification plates, 326f Trailers alignment, 328–330 aluminum sheet and post vans, 321–322 certification plate, 325–326 dump trailers, 326–327 floors, 324–325 FRP plywood trailers, 322–323 lights, 331 overview, 319–320 PMI brakes, 323, 332, 335 extended interval, 334, 336 exterior, 67, 334 front, 331 hubs, 332–333, 335 interior, 333–335 lubrication, 334–336 overview, 330–331 program for, 320 suspension, 331–332, 334–335 tires, 333, 335 undercarriage, 331–332, 334–335 wheels, 333, 335 rear impact guards, 327–328 reflective tape, 330 trailer brakes, 323 van doors, 323–324 Transmission output yoke inspection, 137 Transmissions automatic breathers, 160 cold startup, 156 external lines, 160 governor filters, 158–159 hydraulic fluid recommendations, 156 inspection, 154 maintenance of, 154 oil, 154–157, 159–160 oil coolers, 160 oil filters, 156–157 oil pans, 157–158 lubricants, 135, 363 PMI, 361–362 standard, 135–136 Trans-Synd synthetic oil, 156 Tread depth, 183, 333, 358 Tread design matching, 333, 358 Trunnions, 130–131 TTY (torque-to-yield) bolts, 51 Tubeless demountable adapter cracks, 176 Tubing tools, 24 Turbochargers, 121, 360 Turntable fifth wheels, 281 TVW (towed vehicle weight), 281 20W-20 engine oil, 112 20W-40 engine oil, 112 20W-50 engine oil, 112 Twist drills, 52–53 2-inch diameter plugs, 291f Two-plate clutches, 151f Two-point cab air suspension systems, 218f Two-stage filtering systems, 114 U U-bolts, 243–244, 332 UC (upper coupler) inspection, 344 UHS (Unitized Hub System), 179 U-joints (universal joints), 129–131, 133–134, 228, 362 Ultrasonic leak detectors, 222–223, 322 Ultrasonic thickness testers, 347 Ultraviolet (UV) leak detectors, 222 Undercarriage, 331–332, 334–335, 361–362, 366 Underride guards, 327–328 Unibody construction, 321 Unit ammeters, 312 Unitized Hub System (UHS), 179 Universal joint tools, 34 Universal joints (U-joints), 129–131, 133–134, 228, 362 Unsprung weight, 170, 239 Upper coupler plates, 293, 294f, 331 Upper coupler (UC) inspection, 344 Upper couplers, 278, 347–348 UV (ultraviolet) leak detectors, 222 V V (external visual) inspection, 344 Vacuum system brakes, 196–198 Vacuum testing, 342–343 Vacuum valves, 97, 342f Valve caps, 183, 333, 358 Valve stems, 183 Van doors, 323–324, 331, 334 Van trailers, 320–321 Vehicle overview inspection, 64 Vent doors, 101 Ventilation, 6 Vernier calipers, 36–38 Vibration dampers, 119, 359 Vice Grips, 29 Viscous-type harmonic balancers, 119–120 W Warning labels, battery, 256 Warning lights, 355 Washings, radiator, 95 Water pump pliers, 28 Water pumps, 98–100 Water separators, 115–117 Water spills, 5–6 Water valves, 103 Wear compensators, 139–140, 149–150 Wear patterns, tire, 185f, 358 Weight, air tool, 32 Welding helmets, 4, 5f Welds, damaged, 177 Wet tanks, 198 Wheel alignment, 232–233 Wheel bearings, 128–129, 177–179, 233, 237, 332, 361–362 Wheel lugs, 358–359 Wheel-off incidents, 179 Wheels. See also tires cast spoke, 167–170 disc wheels, 170–176 OOS criteria for, 176–177 overview, 165–166 PMI, 66, 333, 335, 358–359, 365 WHMIS (Workplace Hazardous Material Information Systems), 9 Wide-base wheels, 171–172 Wind chill factor, 90–91 Windows, 357 Windshield wipers, 216, 355–357 Windshields, 217 Winter conditions, 90–91 Wire wheels, 36 Wiring harnesses, 331, 360 Work area safety, 5–6 Work gloves, 3 Work in Progress reminder feature screen, Dossier program, 81f Workplace Hazardous Material Information Systems (WHMIS), 9 Wrenches, 25–28, 42, 51 Y Yield points, 50 Yokes, 129, 131–132 Z Zerk-type grease fittings, 131 0W-30 engine oil, 112 Zinc oxide electrodes, 94 Zipper ruptures, 183 386 Index