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Current technology, especially in our dynamic industry, demands more reliable and up-to-date information in order to operate efficiently. Data of many kinds, from many sources, must be collected, analyzed, and rapidly transmitted into information which can be used to optimize performance and improve our product. To meet these needs in production diesel engine testing, a process control system has been developed around the basic objective of establishing an accurate and regimented test program, which will provide more reliable information for analysis and action, increased test capacity, accurate history data, and a higher quality product. This paper describes the basic design of such a system, the advantages to be gained, and the overall operation.

A foundation of highway truck ride and cab suspension historical evolution is laid describing the influence of marketplace demands, highway conditions, and government laws. Ride quality test methods are revealed along with variables tried and conclusions drawn. These data and techniques are then used to design cab suspension systems for a new line of truck products including both conventional and COE cabs.

This paper describes the procedures used to reduce the tonal noise of a class eight truck engine timing gear train that was initially found to be objectionable under idle operating conditions. Initial measurements showed that the objectionable sounds were related to the fundamental gear mesh frequency, and its second and third harmonics. Experimental and computational procedures used to study and trouble-shoot the problem include vibration and sound measurements, transmission error analysis of the gears under light load condition, and a dynamic analysis of the drive system. Detail applications of these techniques are described in this paper.

The truck flywheel power takeoff has proven itself as a reliable means of supplying continuous power to a variety of mounted equipment. The features of available units are described in detail in an effort to provide the design and application engineer with complete information regarding their function and application, and to stimulate expanded usage of this constant power source.

In an ongoing effort to further improve engine durability, effects on ring wear of various engine operating variables were measured utilizing a radioactive wear test, Due to findings in this wear testing, developments were initiated in air filtration, fluid filtration and oil quality level. Implementation of these changes has improved engine durability.

A new 998 CID V8 engine series has been developed by Mack Trucks, Inc. to supplement its line of heavy duty diesel engines. These engines, the E9 Series, are available in two configurations--a 400 bhp (298 kW) high torque rise version and a 440 bhp (328 kW) conventional torque backup version. Increased horsepower and improved fuel economy were achieved through the development of a chassis mounted charge air cooler and a new four-valve cylinder head. In addition, significant durability improvements were obtained due to the reduced thermal loadings resulting from the lower charge air temperatures. Additional noteworthy features include a new injection pump, improved lube oil system, advanced piston design, and proper selection of seals and gasket materials.

To establish a criteria for engine oil requirements for Mack diesel engines, a program was conducted to establish a specification based on the use of a production multicylinder engine. Laboratory engine tests were supplemented by field tests to assure correlation. Subsequently modifications were made to the engine test procedures to accommodate modifications in engines being marketed. Oil monitoring and oil analysis programs were also implemented to further assist in assuring adequate engine lubrication.

Progression of the successful engine program exemplified by the Mack ENDT675 Maxidyne Six, having an essentially constant horsepower characteristic in the operating speed range, has led to the development and production of the new Mack ENDT865, Maxidyne V-8 having similarly ordered performance at higher output. Significant advances in design to maintain reliability at high loadings including a new injection pump, a simplified oil system, and a single turbocharger arrangement are discussed, as well as a new integral engine brake. The Mack Dynatard Engine Brake is specifically covered in the second part of this paper.