Light and Heavy Vehicle Technology, 4th ed

by Nunney; Malcolm

• ISBN13: 9780750680370
• ISBN10: 0750680377
• Edition: 4th
• Format: Nonspecific Binding
• Copyright: 2006-11-14
• Publisher: Routledge

Summary

Light and Heavy Vehicle Technology, Fourth Edition, provides a complete text and reference to the design, construction and operation of the many and varied components of modern motor vehicles, including the knowledge needed to service and repair them. This book provides incomparable coverage of both cars and heavier vehicles, featuring over 1000 illustrations. This new edition has been brought fully up to date with modern practices and designs, whilst maintaining the information needed to deal with older vehicles. Two entirely new sections of the book provide a topical introduction to alternative power sources and fuels, and battery-electric, hybrid and fuel-cell vehicles. More information on the latest developments in fuel injection, diesel engines and transmissions has also been added. An expanded list of technical abbreviations now contains over 200 entries a useful resource for professional technicians in their day-to-day work. This book is an essential textbook for all students of automotive engineering, particularly on IMI / C&G 4000 series and BTEC courses and provides all the underpinning knowledge required for NVQs to level 3. By bridging the gap between basic and more advanced treatments of the subject, it also acts as a useful source of information for experienced technicians and technically minded motorists, and will help them to improve their knowledge and skills. Incomparable breadth and depth of coverage, with over 1000 illustrations The core book for all students of automotive engineering up to level 3 This new edition covers the latest developments in alternative power sources and fuels, diesel systems and transmissions

Table of Contents

Preface	ix
Acknowledgements	x
Automotive technical abbreviations	xi
The reciprocating piston petrol engine	1	(70)
Modern requirements	1	(1)
Engine nomenclature	2	(2)
Operating principles	4	(5)
Basic structure and mechanism	9	(3)
Cylinder and crankthrow arrangements	12	(4)
Cylinder block, crankcase and head	16	(10)
Pistons and connecting rods	26	(9)
Crankshaft assembly and main bearings	35	(9)
Crankshaft torsional vibration dampers	44	(3)
Valve train	47	(13)
Timing drive	60	(6)
The principles of valve timing	66	(5)
The diesel engine	71	(15)
Suitability for road transport	71	(1)
Operating principles	71	(3)
Cylinder block, crankcase and head	74	(3)
Pistons and connecting rods	77	(3)
Crankshaft assembly and main bearings	80	(2)
Valve train and timing drive	82	(4)
Combustion chambers and processes	86	(14)
Basic layouts of combustion chambers	86	(1)
Combustion in the petrol engine	87	(2)
Petrol engine combustion chambers	89	(5)
Combustion in the diesel engine	94	(1)
Diesel engine combustion chambers	95	(3)
Cylinder charge agitation	98	(2)
Engine lubrication	100	(24)
Friction and wear	100	(1)
The lubrication process	100	(2)
Engine lubricating oils	102	(4)
Engine lubrication systems	106	(8)
Oil pumps and pressure relief valves	114	(3)
Oil filtration and cooling	117	(2)
Oil retention and crankcase ventilation	119	(5)
Engine cooling, vehicle heating and air conditioning	124	(32)
Heat transfer and cooling media	124	(1)
Engine air-cooling system	125	(2)
Engine water-cooling system	127	(12)
Engine cooling systems for passenger cars and heavy vehicles	139	(2)
Engine coolant	141	(2)
Interior ventilation and heating	143	(4)
Introduction to passenger car air conditioning systems	147	(1)
Principles of refrigerated air conditioning	147	(1)
Refrigerated air conditioning system components	148	(5)
Full air conditioning systems	153	(1)
Commercial vehicle refrigeration units	153	(3)
Carburation and fuel injection	156	(27)
Fuel supply system	156	(6)
Fixed-choke carburettors	162	(6)
Variable-choke carburettors	168	(3)
Multiple and compound carburettors	171	(2)
Electronically controlled carburettors	173	(1)
Petrol engine fuel injection	173	(2)
Multi-point fuel injection	175	(3)
Single-point fuel injection	178	(2)
Direct fuel injection	180	(1)
Electronic throttle control	181	(2)
Intake and exhaust systems	183	(10)
Air cleaner and silencer	183	(2)
Intake and exhaust manifolds	185	(4)
Exhaust system	189	(2)
Vacuum gauge and exhaust gas analyser	191	(2)
Diesel fuel injection systems	193	(30)
Fuel injection systems	193	(1)
Fuel supply system	193	(3)
In-line fuel injection pump	196	(4)
Governing the in-line fuel injection pump	200	(5)
Distributor fuel injection pump	205	(2)
Governing the distributor fuel injection pump	207	(1)
Timing in-line and distributor fuel injection pumps	208	(1)
Fuel injectors for jerk pump systems	209	(4)
Unit fuel injection	213	(2)
Introduction to electronic diesel control	215	(3)
Common rail fuel injection	218	(2)
Cold starting devices	220	(3)
Forced induction	223	(9)
Natural aspiration and forced induction	223	(1)
Methods of pressure charging	223	(9)
Ignition and starter systems	232	(23)
Coil ignition equipment	232	(1)
Ignition coil and capacitor	233	(3)
Ignition distributor and sparking plugs	236	(7)
Introduction to electronic ignition systems	243	(2)
Types of electronic ignition system	245	(2)
Ignition timing	247	(2)
Damp ignition in service	249	(1)
The starter system	249	(6)
Engine emission control	255	(6)
Petrol engine pollutants	255	(1)
Petrol engine emission control	256	(2)
Diesel engine pollutants	258	(1)
Diesel particulate filters	259	(2)
Rotary piston engine	261	(4)
Rotary piston engine	261	(4)
Friction clutches	265	(23)
Types of single-plate clutch	265	(3)
Clutch control systems	268	(7)
Clutch centre plate construction	275	(4)
Direct-release clutch	279	(1)
Centrifugally operated clutches	279	(1)
Multiplate clutches	280	(2)
Angle spring clutch	282	(1)
Clutch misbehaviour in service	282	(4)
Flywheel and clutch housing alignment	286	(2)
Layshaft gearboxes	288	(29)
Purpose and elements of the gearbox	288	(4)
Constant-mesh gearboxes	292	(5)
Synchromesh gearboxes	297	(6)
Gear selector mechanisms	303	(5)
Heavy-vehicle gearboxes	308	(5)
Gearbox lubrication and sealing	313	(3)
Gearbox misbehaviour in service	316	(1)
Fluid couplings and torque converters	317	(9)
Fluid couplings	317	(2)
Improvements to fluid couplings	319	(1)
Torque converters	319	(4)
Improvements to torque converters	323	(1)
Fluid couplings and torque converters in service	323	(3)
Epicyclic gearboxes	326	(14)
Basic epicyclic gearing	326	(1)
Operation of epicyclic gear trains	327	(8)
Friction brakes for epicyclic gearboxes	335	(5)
Semi-automatic and automatic transmissions	340	(31)
Semi-automatic transmissions for passenger cars	340	(1)
Semi-automatic transmissions for heavy vehicles	341	(3)
Automatic transmissions for passenger cars	344	(3)
Hydraulic control systems	347	(7)
Electrohydraulic control systems	354	(2)
Automatic transmission fluid	356	(2)
Checking the level and changing the fluid	358	(1)
Automatic layshaft gearboxes	359	(1)
Dual mode transmissions with sequential gearchange	359	(2)
Direct shift gearbox	361	(2)
Continuously and infinitely variable transmissions	363	(8)
Overdrive gears	371	(8)
Purpose and position of an overdrive gear	371	(1)
Epicyclic overdrive gears	372	(2)
Layshaft overdrive gears	374	(3)
Automatic transmission overdrive gears	377	(2)
Drive lines	379	(24)
Universal joints	379	(3)
Constant-velocity joints	382	(7)
Propeller shaft construction	389	(3)
Drive line arrangements	392	(4)
Rear-wheel drive and front-wheel drive layouts	396	(3)
Front-wheel drive shafts	399	(1)
Tandem axle drives for heavy vehicles	400	(1)
Drive lines for public service vehicles	401	(2)
Final drives and rear axles	403	(28)
Final drive gears and bearings	403	(5)
Adjusting the final drive gears	408	(6)
Differential gears	414	(4)
Rear axle construction	418	(5)
Final drive lubrication and sealing	423	(2)
Rear axle misbehaviour in service	425	(1)
Heavy-vehicle rear axles	426	(5)
Four-wheel-drive systems	431	(11)
Types of four-wheel drive	431	(1)
Basic considerations of four-wheel drive	432	(1)
Part-time four-wheel drive	433	(2)
Full-time four-wheel drive	435	(7)
Tyres, road wheels and hubs	442	(19)
Tyre requirements	442	(1)
Introduction to tyre characteristics	442	(2)
Tyre construction	444	(8)
Road wheels and hubs	452	(5)
Wheel balancing	457	(2)
Safety precautions in tyre servicing	459	(2)
Suspension systems	461	(35)
Basic ride considerations	461	(1)
Types of suspension	461	(11)
Basic handling considerations	472	(1)
Types of suspension spring	472	(14)
Tandem axle suspension	486	(3)
Shock dampers	489	(4)
Adaptive suspension systems	493	(1)
Active roll control systems	494	(1)
Suspension misbehaviour in service	495	(1)
Manual steering	496	(25)
Steering principles and layout	496	(3)
Front end geometry and wheel alignment	499	(7)
Steering and suspension ball joints	506	(3)
Manual steering gears	509	(6)
Inspecting and adjusting the steering mechanism	515	(3)
Conventionally steered and self-steering axles for heavy vehicles	518	(1)
Steering wheel airbags	519	(2)
Power-assisted steering	521	(22)
The need for power-assisted steering	521	(1)
Principles of hydraulic power-assisted steering	521	(3)
Hydraulic power-assisted steering components	524	(8)
Speed-sensitive hydraulic power-assisted steering	532	(4)
Hydraulic power-assisted steering misbehaviour in service	536	(1)
Electro-hydraulic power-assisted steering	536	(2)
Introduction to electrical power-assisted steering	538	(1)
Electrical power-assisted steering components	539	(1)
Types of electrical power-assisted steering	540	(3)
Four-wheel-steering systems	543	(9)
The need for four-wheel steering	543	(4)
Types of four-wheel steering	547	(5)
Hydraulic brake systems	552	(39)
Drum brake arrangements	552	(7)
Disc brake arrangements	559	(6)
Brake friction materials	565	(1)
Hydraulic brake systems and components	566	(11)
Hydraulic brake fluids	577	(2)
Vacuum servo-assisted braking	579	(3)
The parking brake system	582	(2)
Hydraulic power brakes	584	(2)
Maintenance of hydraulic brakes	586	(3)
Brake efficiency and testing	589	(2)
Air and endurance brake systems	591	(23)
Principles of air brakes	591	(1)
Compression and storage	592	(2)
System control	594	(6)
System actuation	600	(5)
Hand-operated brake valves and other equipment	605	(1)
Air disc brakes	606	(4)
Endurance brake systems	610	(4)
Anti-lock brakes and traction control	614	(11)
Background to anti-lock braking	614	(1)
Basic components of anti-lock brake systems	614	(1)
Types of anti-lock brake systems	615	(3)
Output control channels for antilock brakes	618	(2)
Anti-lock air brakes for heavy vehicles	620	(1)
Traction control systems	621	(1)
Vehicle dynamics control	622	(3)
Vehicle structure and aerodynamics	625	(27)
Integral body construction	625	(11)
Aluminium body construction	636	(2)
Multi-purpose vehicles	638	(1)
Commercial vehicle chassis frames	638	(6)
Trailer and caravan couplings	644	(4)
Introduction to vehicle aerodynamics	648	(1)
Basic considerations of vehicle aerodynamics	649	(1)
Aerocoustics	650	(1)
Heavy vehicle aerodynamics	651	(1)
Alternative power sources and fuels	652	(3)
General background	652	(1)
Modern requirements for alternative fuels	652	(1)
Classification of alternative fuels	653	(2)
Battery-electric, hybrid and fuel-cell vehicles	655	(6)
General background	655	(1)
Battery-electric vehicles	655	(1)
Layout of battery-electric vehicles	655	(1)
Basic units of battery-electric vehicles	655	(2)
Hybrid-electric vehicles	657	(1)
Layout of hybrid-electric vehicles	657	(1)
Basic units of hybrid-electric vehicles	658	(1)
Fuel-cell vehicles	659	(1)
Operation and types of fuel-cell	659	(1)
Layout of fuel-cell vehicles	660	(1)
Index	661