Light and Heavy Vehicle Technology

684 Pages·2006·11.58 MB·English

by  Malcolm Nunney

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Light and Heavy
Vehicle Technology
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When theory and practice do not agree, you should examine the facts
to see what is wrong with the theory
Charles F. Kettering, General Motors (1934)
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Light and Heavy
Vehicle Technology
Fourth edition
M.J. Nunney
CGIA, MSAE, MIMI
Amsterdam • Boston • Heidelberg • London • New York • Oxford
Paris • San Diego • San Francisco • Singapore • Sydney • Tokyo
Butterworth-Heinemann is an imprint of Elsevier
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Butterworth-Heinemann is an imprint of Elsevier
Linacre House, Jordan Hill, Oxford OX2 8DP
30 Corporate Drive, Suite 400, Burlington, MA 01803
First published 1988
Reprinted 1991
Second edition 1992
Third edition 1998
Reprinted 1998, 2000, 2001, 2002, 2003, 2004, 2005
Fourth edition 2007
Copyright © 2007, M.J. Nunney. Published by Elsevier Ltd. All rights reserved.
The right of M.J. Nunney to be identified as the author of this work has been asserted in
accordance with the Copyright, Designs and Patents Act 1988.
No part of this publication may be reproduced, stored in a retrieval system,
or transmitted in any form or by any means electronic, mechanical, photocopying,
recording or otherwise without the prior written permission of the publisher.
Permissions may be sought directly from Elsevier’s Science & Technology
Rights Department in Oxford, UK: phone (⫹44) (0) 1865 843830;
fax (⫹44) (0) 1865 853333; email:
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Contents
Preface IX 5 Engine cooling, vehicle heating and air
Acknowledgements X conditioning 124
Automotive technical abbreviations XI
5.1 Heat transfer and cooling media 124
5.2 Engine air-cooling system 125
1 The reciprocating piston petrol engine 1
5.3 Engine water-cooling system 127
5.4 Engine cooling systems for passenger
1.1 Modern requirements 1
cars and heavy vehicles 139
1.2 Engine nomenclature 2
5.5 Engine coolant 141
1.3 Operating principles 4
5.6 Interior ventilation and heating 143
1.4 Basic structure and mechanism 9
5.7 Introduction to passenger car air
1.5 Cylinder and crankthrow arrangements 12
conditioning systems 147
1.6 Cylinder block, crankcase and head 16
5.8 Principles of refrigerated air conditioning 147
1.7 Pistons and connecting rods 26
5.9 Refrigerated air conditioning system
1.8 Crankshaft assembly and main bearings 35
components 148
1.9 Crankshaft torsional vibration dampers 44
5.10 Full air conditioning systems 153
1.10 Valve train 47
5.11 Commercial vehicle refrigeration units 153
1.11 Timing drive 60
1.12 The principles of valve timing 66
6 Carburation and fuel injection 156
2 The diesel engine 71 6.1 Fuel supply system 156
6.2 Fixed-choke carburettors 162
2.1 Suitability for road transport 71 6.3 Variable-choke carburettors 168
2.2 Operating principles 71 6.4 Multiple and compound carburettors 171
2.3 Cylinder block, crankcase and head 74 6.5 Electronically controlled carburettors 173
2.4 Pistons and connecting rods 77 6.6 Petrol engine fuel injection 173
2.5 Crankshaft assembly and main 6.7 Multi-point fuel injection 175
bearings 80 6.8 Single-point fuel injection 178
2.6 Valve train and timing drive 82 6.9 Direct fuel injection 180
6.10 Electronic throttle control 181
3 Combustion chambers and processes 86
7 Intake and exhaust systems 183
3.1 Basic layouts of combustion chambers 86
7.1 Air cleaner and silencer 183
3.2 Combustion in the petrol engine 87
7.2 Intake and exhaust manifolds 185
3.3 Petrol engine combustion chambers 89
7.3 Exhaust system 189
3.4 Combustion in the diesel engine 94
7.4 Vacuum gauge and exhaust gas analyser 191
3.5 Diesel engine combustion chambers 95
3.6 Cylinder charge agitation 98
8 Diesel fuel injection systems 193
4 Engine lubrication 100 8.1 Fuel injection systems 193
8.2 Fuel supply system 193
4.1 Friction and wear 100 8.3 In-line fuel injection pump 196
4.2 The lubrication process 100 8.4 Governing the in-line fuel injection pump 200
4.3 Engine lubricating oils 102 8.5 Distributor fuel injection pump 205
4.4 Engine lubrication systems 106 8.6 Governing the distributor fuel injection pump 207
4.5 Oil pumps and pressure relief valves 114 8.7 Timing in-line and distributor fuel
4.6 Oil filtration and cooling 117 injection pumps 208
4.7 Oil retention and crankcase 8.8 Fuel injectors for jerk pump systems 209
ventilation 119 8.9 Unit fuel injection 213
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VI C O N T E N T S
8.10 Introduction to electronic diesel control 215 15.4 Improvements to torque converters 323
8.11 Common rail fuel injection 218 15.5 Fluid couplings and torque converters
8.12 Cold starting devices 220 in service 323
9 Forced induction 223 16 Epicyclic gearboxes 326
9.1 Natural aspiration and forced induction 223 16.1 Basic epicyclic gearing 326
9.2 Methods of pressure charging 223 16.2 Operation of epicyclic gear trains 327
16.3 Friction brakes for epicyclic gearboxes 335
10 Ignition and starter systems 232
17 Semi-automatic and automatic
10.1 Coil ignition equipment 232 transmissions 340
10.2 Ignition coil and capacitor 233
10.3 Ignition distributor and sparking plugs 236 17.1 Semi-automatic transmissions for
10.4 Introduction to electronic ignition systems 243 passenger cars 340
10.5 Types of electronic ignition system 245 17.2 Semi-automatic transmissions for heavy
10.6 Ignition timing 247 vehicles 341
10.7 Damp ignition in service 249 17.3 Automatic transmissions for
10.8 The starter system 249 passenger cars 344
17.4 Hydraulic control systems 347
11 Engine emission control 255 17.5 Electrohydraulic control systems 354
17.6 Automatic transmission fluid 356
11.1 Petrol engine pollutants 255 17.7 Checking the level and changing the fluid 358
11.2 Petrol engine emission control 256 17.8 Automatic layshaft gearboxes 359
11.3 Diesel engine pollutants 258 17.9 Dual mode transmissions with
11.4 Diesel particulate filters 259 sequential gearchange 359
17.10 Direct shift gearbox 361
17.11 Continuously and infinitely variable
12 Rotary piston engine 261
transmissions 363
12.1 Rotary piston engine 261
18 Overdrive gears 371
13 Friction clutches 265
18.1 Purpose and position of an overdrive gear 371
18.2 Epicyclic overdrive gears 372
13.1 Types of single-plate clutch 265
18.3 Layshaft overdrive gears 374
13.2 Clutch control systems 268
18.4 Automatic transmission overdrive gears 377
13.3 Clutch centre plate construction 275
13.4 Direct-release clutch 279
13.5 Centrifugally operated clutches 279 19 Drive lines 379
13.6 Multiplate clutches 280
13.7 Angle spring clutch 282 19.1 Universal joints 379
13.8 Clutch misbehaviour in service 282 19.2 Constant-velocity joints 382
13.9 Flywheel and clutch housing alignment 286 19.3 Propeller shaft construction 389
19.4 Drive line arrangements 392
14 Layshaft gearboxes 288 19.5 Rear-wheel drive and front-wheel
drive layouts 396
14.1 Purpose and elements of the gearbox 288 19.6 Front-wheel drive shafts 399
14.2 Constant-mesh gearboxes 292 19.7 Tandem axle drives for heavy vehicles 400
14.3 Synchromesh gearboxes 297 19.8 Drive lines for public service vehicles 401
14.4 Gear selector mechanisms 303
14.5 Heavy-vehicle gearboxes 308 20 Final drives and rear axles 403
14.6 Gearbox lubrication and sealing 313
14.7 Gearbox misbehaviour in service 316
20.1 Final drive gears and bearings 403
20.2 Adjusting the final drive gears 408
15 Fluid couplings and torque converters 317 20.3 Differential gears 414
20.4 Rear axle construction 418
15.1 Fluid couplings 317 20.5 Final drive lubrication and sealing 423
15.2 Improvements to fluid couplings 319 20.6 Rear axle misbehaviour in service 425
15.3 Torque converters 319 20.7 Heavy-vehicle rear axles 426
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C O N T E N T S VII
21 Four-wheel-drive systems 431 26 Four-wheel-steering systems 543
21.1 Types of four-wheel drive 431 26.1 The need for four-wheel
21.2 Basic considerations of four-wheel drive 432 steering 543
21.3 Part-time four-wheel drive 433 26.2 Types of four-wheel steering 547
21.4 Full-time four-wheel drive 435
27 Hydraulic brake systems 552
22 Tyres, road wheels and hubs 442
27.1 Drum brake arrangements 552
22.1 Tyre requirements 442
27.2 Disc brake arrangements 559
22.2 Introduction to tyre characteristics 442
27.3 Brake friction materials 565
22.3 Tyre construction 444
27.4 Hydraulic brake systems and
22.4 Road wheels and hubs 452
components 566
22.5 Wheel balancing 457
27.5 Hydraulic brake fluids 577
22.6 Safety precautions in tyre servicing 459
27.6 Vacuum servo-assisted braking 579
27.7 The parking brake system 582
27.8 Hydraulic power brakes 584
23 Suspension systems 461
27.9 Maintenance of hydraulic brakes 586
27.10 Brake efficiency and testing 589
23.1 Basic ride considerations 461
23.2 Types of suspension 461
23.3 Basic handling considerations 472
28 Air and endurance brake systems 591
23.4 Types of suspension spring 472
23.5 Tandem axle suspension 486
28.1 Principles of air brakes 591
23.6 Shock dampers 489
28.2 Compression and storage 592
23.7 Adaptive suspension systems 493
28.3 System control 594
23.8 Active roll control systems 494
28.4 System actuation 600
23.9 Suspension misbehaviour in service 495
28.5 Hand-operated brake valves and other
equipment 605
28.6 Air disc brakes 606
24 Manual steering 496
28.7 Endurance brake systems 610
24.1 Steering principles and layout 496
24.2 Front end geometry and wheel alignment 499
29 Anti-lock brakes and traction control 614
24.3 Steering and suspension ball joints 506
24.4 Manual steering gears 509
29.1 Background to anti-lock braking 614
24.5 Inspecting and adjusting the steering
29.2 Basic components of anti-lock brake
mechanism 515
systems 614
24.6 Conventionally steered and self-steering
29.3 Types of anti-lock brake systems 615
axles for heavy vehicles 518
29.4 Output control channels for anti-
24.7 Steering wheel airbags 519
lock brakes 618
29.5 Anti-lock air brakes for heavy
25 Power-assisted steering 521 vehicles 620
29.6 Traction control systems 621
25.1 The need for power-assisted steering 521 29.7 Vehicle dynamics control 622
25.2 Principles of hydraulic power-
assisted steering 521
25.3 Hydraulic power-assisted steering 30 Vehicle structure and aerodynamics 625
components 524
25.4 Speed-sensitive hydraulic power- 30.1 Integral body construction 625
assisted steering 532 30.2 Aluminium body construction 636
25.5 Hydraulic power-assisted steering 30.3 Multi-purpose vehicles 638
misbehaviour in service 536 30.4 Commercial vehicle chassis frames 638
25.6 Electro-hydraulic power-assisted steering 536 30.5 Trailer and caravan couplings 644
25.7 Introduction to electrical power-assisted 30.6 Introduction to vehicle aerodynamics 648
steering 538 30.7 Basic considerations of vehicle
25.8 Electrical power-assisted steering aerodynamics 649
components 539 30.8 Aerocoustics 650
25.9 Types of electrical power-assisted steering 540 30.9 Heavy vehicle aerodynamics 651
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VIII C O N T E N T S
31 Alternative power sources and fuels 652 32.3 Layout of battery-electric vehicles 655
32.4 Basic units of battery-electric vehicles 655
31.1 General background 652 32.5 Hybrid-electric vehicles 657
31.2 Modern requirements for alternative fuels 652 32.6 Layout of hybrid-electric vehicles 657
31.3 Classification of alternative fuels 653 32.7 Basic units of hybrid-electric vehicles 658
32.8 Fuel-cell vehicles 659
32.9 Operation and types of fuel-cell 659
32 Battery-electric, hybrid and fuel-cell vehicles 655
32.10 Layout of fuel-cell vehicles 660
32.1 General background 655
32.2 Battery-electric vehicles 655 Index 661
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Preface
The purpose of this new fourth edition of Light and Heavy Two entirely new sections of the book provide a topical
Vehicle Technology remains one of providing readily accessi- introduction to alternative power sources and fuels, and battery-
ble information, which bridges the gap between the purely electric, hybrid and fuel-cell vehicles. Also, the number of
basic and the more advanced treatments of the subject. By entries in the list of automotive technical abbreviations has
understanding the reasons behind the design, construction now increased to over 200. Finally, as in previous editions of
and operation of the many and varied components of modern the book, the tradition of including brief historical notes on
motor vehicles, the technician should be better equipped to the development of modern automotive concepts has been
deal with their servicing and overhaul. Some references to continued.
past automotive practice have been retained, not only M.J. Nunney
because a technician may still be required to test and repair
older vehicles, but also to provide a convenient transition to
later practice.
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