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Man 5 ton by Mind Map: Man 5 ton

1. Engine system D-0836LFL04 Euro2 267Hp

1.1. Fuel system

1.1.1. Fuel injection pump

1.2. Cooling system

1.2.1. Fan

1.2.2. Water pump

1.3. Air intake system

1.3.1. Air filter Turbocharger Intake air required for combustion process is cooled to approx.50 Intercooler

1.4. Lubricating system

1.4.1. Component Gear oil pump Pressure relief valve Heat exchanger Oil filter By pass valve Switch for oil pressure warning light Main oil duct

1.4.2. Function Minimize wear and tear Minimize power loss Remove heat (cooling system) Provide good seal between piston and cylinder wall

1.5. EDC ( electronic diesel control)

1.5.1. Pump control unit

1.5.2. Fuel injection pump

1.5.3. Optimum injection moment and optimum injection volume

1.6. Exhaust system

1.6.1. Exhaust manifold Resonator Muffler

1.7. To the transmission

1.7.1. transfer case axle wheel

1.8. Engine control unit

1.8.1. Accelerator pedal setting

1.8.2. Boost pressure

1.8.3. Boost air temperature

1.8.4. Water temperature

1.8.5. Fuel temperature

1.8.6. Road speed

1.8.7. Brake actuation

1.8.8. Clutch actuation

1.8.9. Retarder actuation

1.8.10. RSG/RSL Switch

1.8.11. engine sensor Engine actuators

1.8.12. CTIS central tyre inflation system

1.8.13. THE EDC control unit controls and monitor the entire operation of the injection system. It receives various signals from sensor. The EDC will evaluates the date it receives and controls the linear magnet in the regulator depending on the tired data and characteristic map

2. Allison Transmission Gen3

2.1. Torque couple with engine

2.1.1. Rotatable clutches Planetary gear p1,p2,p3 Output Control module Solenoid Connected to the ECU

2.1.2. Impeller Driven by the flywheel and act as a centrifugal pump when impeller turn, it draws fluid from the TC housing Fluid enter impeller valves, centrifugal force direct the fluid towards the turbine

2.1.3. Turbine Connected to the transmission input shaft fluid throw out from the impeller entere the turbine Change of direction causes turbine to move

2.1.4. Stator Resides in the center of torque converter to redirect fluid returning from turbine before hitting the pump again increasing the efficiency of the torque converter Without stator, at starting speed fluid leaves turbine would resist the rotation of impeller

3. Transfer gearbox

3.1. Axel

3.1.1. Front

3.1.2. Bsck

4. Break system

4.1. Service brake system SBS

4.1.1. foot brake valve brake

4.1.2. Power reservoir

4.1.3. Circuit safety valve

4.1.4. Power regulator

4.1.5. Brake cylinder

4.2. Parking break system PBS

4.2.1. Hand break valve relay valve

4.2.2. Combination cylinder

4.3. Emergency brake system EBS

4.3.1. Part of the service brake system or parking break system

4.4. Antilock Brake system ABS DSC sensor

4.4.1. magnet wheel

4.4.2. rpm

4.5. Additional equipment

4.5.1. Air suspension

4.5.2. power clutch

4.5.3. Door closing system

4.6. Drive slip regulator

4.6.1. Electronic control unit

4.6.2. Pressure control valve

4.6.3. DSC brake valve

4.6.4. DSC motor control

4.7. Air supply unit

4.7.1. Compressor

4.7.2. Air dryer or anti freeze pump and pressure regulator

4.8. Start

4.8.1. Air compressor Air dryer Air reservoir

4.9. Function

4.9.1. it is to slow the vehicle or to stop the vehicle without skidding

5. Steering system

5.1. An engine driven pump

5.2. A control valve

5.3. A double acting power cylinder

5.4. A reservoir

6. Electrical system

6.1. Batteries

6.1.1. 24 Volt

6.2. Lighting system

6.3. CAN

6.3.1. ABS/ASR Control unit Processes the signal from speed sensor to detect when one or more wheels are tending to slip. It will calculate the control signal for the pressure control valves

6.3.2. Allison gearbox control unit

6.3.3. Automatic drive train management

6.3.4. EDC electronic diesel control

6.4. ADM

6.4.1. Spitter box Sharing of adm and abs for wheel sensor

6.4.2. Control unit

6.4.3. Advantage of adm 100% of drive torque is transmitted Automatic actuation is made possible on the basis of spin control and can be activated up to permitted max speed System only activate when the driving situation demands it. It is deactivated automatically afterwards Safeguard against incorrect operation and cannot be influenced by the driver Inadvertent engagement and disengagement of differential lock are avoided Less wear and tear on drive train

6.5. Charging system

6.5.1. Alternator The stator Rotore End frame

6.5.2. Engine drives rotor Rotor turn inside the stator AC current is produced by the north and south pole

7. Two types of maintenance

7.1. CM

7.1.1. 20 core task Removal and install air con compressor belt Removal and install alternator belt Removal and install alternator assembly Removal of fuel injection pump Removal and install radiator Removal and install exhaust brake cylinder and butterfly valve Removal and install EDC ECU Removal and install ADM ECU Removal and install of Allison automatic transmission Removal and install transfer case Removal and install selector level and speed sensor Removal and install spare tyre Removal and install front brake booster Removal and install rear brake booster Removal and install break pressure sensor Removal and install road wheel Removal and install tyre valve Removal and install batteries Removal and install starter motor Removal and install starter switch

7.2. PM

7.2.1. 5k

7.2.2. 10k

7.2.3. 15k

7.2.4. 20k

7.2.5. 25k

7.2.6. 30k

7.2.7. 35k

7.2.8. 40k

8. Safety precautions

8.1. Level ground

8.2. Wheel choke

8.3. Parking break

8.4. Neutral gear

8.5. Remove ignition key

8.6. Disconnect negative terminal

9. Sensor

9.1. 3 types of speed sensor

9.1.1. Engine speed Generated by the rips on the shell of the torque converter pump

9.1.2. Turbine speed Generated by the rotating-clutch housing splint contours

9.1.3. Output speed Generated by the toothed member attached to the output shaft

9.2. Throttle position sensor

9.2.1. Mounted to the engine,chassis or transmission

9.2.2. Contain a pull actuation cable and potentiometer

10. Diagnostic testing

10.1. BIT Allison transmission Build in tester

10.1.1. To check for oil level and temperature If system is ready it will show OL-OK If oil temperature reach 60 degree to 104 degree ( Transmission gauge located on the extreme RHS of the instrument panal) If oil level is Low by one quart (0.946 litres) it will indicate OL-LO1 If oil level is high by one quart it will indicate OL-HI1 If oil level too Low will indicate OL-70 Reference to operation manual page 4.21-1 or MAN 5 Ton manual volume 2 page 5-4

10.1.2. Diagnostics check for faults PRESS BIT diagnostic teice If no fault D1 - - If fault D1 - 2 2 1 4 Press mode button again for D2 and repeat until D5 BIT Can check the maximum of 5 fault All diagnostic code can be found on man 5 ton Manual volume 2 page 6-4 to 6-14

10.2. FCR

10.2.1. ADM Automatic drive-train management

10.2.2. EDC Electronic diesel control Component EDC checks Engine Speed sensor Pedal valve sensor needle movement sensor coolant temperature sensor injector control level

10.2.3. ABS Anti-Lock Braking system

10.3. MANCAT