MediumHeavy Duty Truck Engines, Fuel & Computerized Management Systems

1018 Pages·2012·185.57 MB·English

by  Sean Bennett

Vertical Back of Cab Rear Geartrain
Catalyzed DPF
Camshaft
gear
Camshaft
idler gear
REPTO
gear
Lower
idler gear
(outer and
inner)
Air compressor gear Crankshaft
gear
Servo pump idler gear
Oil pump
gear
Servo pump gear
MP8 Oil Flow Schematic
MAIN LUBRICATION LUBRICATION SYSTEM
SYSTEM COMPONENTS VALVE ARRANGEMENT
1. Oil pan pickup strainer 8. Main lubrication galley A. Reducing valve
2. Pickup tube 9. Crankcase ventilation B. Safety valve
3456.... LPOFuirileltb ecsrrois chuoaorlteeiunr spgiin pogeil pump 111 1 02 . .. VAsBeGiyrpp Tcaaorsamst pofirrle ttesursrboirne CDEF.... POTOihspveteeorrnnmfil nocogwos ot vavlaiatn llvvgveae c l vfofoeonr r tf profouirsl l lto vofiallnol vwceo foiltlienrg © Mack Trucks, Inc.
7. Full flow oil filters 13. Nozzles to spray pistons
Figure C–1  DPF, rear geartrain, and lube circuit on a Mack Trucks MP8 engine. 
1
Copyright 2012 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.
Bearing structure C2-1 High mileage wear: lead-tin bond C2-2
weakens in high load area
Sliding contact stress fatigue C2-3 High mileage, normal wear: wear in C2-4
caused by normal, high mileage high load areas with some cavitation
wear
Caterpillar Inc.
Courtesy of
Reprinted
©
Misaligned loading: wear occurs on C2-5 Thermal growth (overheating) of C2-6
opposite sides aluminum layer causes bond
separation
Figure C–2  Bearing failure analysis.
2
Copyright 2012 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.
Value terminology C3-1 Valve closing stress points C3-2
Stress during combustion C3-3 Thermal cracks caused by C3-4
overheating
Caterpillar Inc.
Courtesy of
Reprinted
©
Cupping or dishing: also caused C3-5 Valve leakage effects caused by ash C3-6
by overheating and carbon build-up valve face
Figure C–3  Valve failure analysis.
3
Copyright 2012 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.
Piston ring Piston ring seals
Bushing
Cam gear
Control valve
Crank seal
Crankshaft
Unison ring
Turbine
wheel
Pin
Vanes
Caterpillar Inc.
Courtesy of
Reprinted
©
Figure C–4  Variable nozzle turbocharger operation.
4
Copyright 2012 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.
Scania
© Illustration courtesy of
Figure C5–1  Location of turbo-compound circuit 
on a typical engine.
To engine
intake circuit
Engine
exhaust gas
Fluid
coupling
Torque To exhaust
assist to after treatment
engine circuit
crankshaft
Scania
© Illustration courtesy of
Figure C5–2  Holset Turbocompounding.  5
Copyright 2012 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.
Cengage Learning 2013
©
Figure C6–1  The heart of the amplified common rail fuel system used on Detroit 
Diesel’s DD15 engine. 
Cengage Learning 2013
©
Figure C6–2  The unique compounded turbocharger used on the DD15 in which 
turboboost is harnessed to impart drive torque to the engine by means of its geartrain.
6
Copyright 2012 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.
Series
turbochargers
CGI
CGI
mixing
cooler
valve
C
A
A CGI
T
A venturi
C C
T T
Diesel
particulate
filter
Intake valve High pressure
OCV
actuation injection system
filter
CRS
system
Plate type
oil cooler
Charge air
ccooonlneerction Caterpillar Inc.
CGI connectionCGI cooler Dual oil filters Reprinted Courtesy of
©
Figure C–7  Caterpillar ACERT on post-2007, C13 engine.
7
Copyright 2012 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.
Q Technologies brand
XI
E
N
Snap-on Inc./
©
Figure C8–1  A basic handheld EST, the Blue-Point™ POCKET iQ showing some of 
the data it can scan.
ms Inc
Syste
Noregon
Courtesy of
©
Figure C8–2  More advanced generic J-Pro Fleet Diagnostics PC software screen (center of image) 
showing some of the fields it is capable of displaying.
8
Copyright 2012 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.