vehicle

Abstract

A suspension assembly for a vehicle includes a lower alignment arm, an upper alignment arm, and a linear force element. The lower alignment arm includes a first portion, a second portion, a third portion, and a linear force element holder. The linear force element holder includes a bearing for pivotally connecting the linear force element to the lower alignment arm.

Description

[0001] Cross-reference to related applications

[0002] This application is a partial successor to U.S. Patent Application No. 16 / 861,859, filed April 29, 2020, entitled “Vehicle”, which claims priority to U.S. Provisional Patent Application No. 62 / 840,654, filed April 39, 2019, entitled “Vehicle”, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to side-by-side vehicles and all-terrain vehicles. Background Technology

[0004] Typically, all-terrain vehicles (ATVs) and multi-purpose vehicles (UVs) are used to transport one or two passengers and a small amount of cargo across various terrains. Due to growing interest in ATVs, specialized ATVs, such as those for off-road driving, racing, and cargo hauling, have entered the market. Most ATVs include seating for up to two passengers, who can sit side-by-side or behind the driver. Side-by-side ATVs, where the driver and passengers sit next to each other in laterally spaced seats, have become popular because they allow passengers to share the driver's view. Summary of the Invention

[0005] In one embodiment of this disclosure, a suspension arm for a vehicle includes a first portion and a second portion coupled to the first portion. The first and second portions together define an upper surface of the suspension arm.

[0006] In a further embodiment of this disclosure, a suspension assembly for a vehicle includes an alignment arm, the alignment arm comprising a mounting assembly having a bearing plate and a bearing member. The bearing member is removably coupled within a portion of the bearing plate. The suspension assembly further includes a linear force element movably coupled to the alignment arm at the bearing member.

[0007] In another embodiment of this disclosure, a suspension arm for a vehicle includes an upper portion and a lower portion. An upper range of the lower portion overlaps with a lower range of the upper portion to define an overlapping side of the upper and lower portions. The upper portion is connected to the lower portion at the overlapping side.

[0008] In yet another embodiment of this disclosure, a method of assembling a suspension arm for a vehicle includes: providing a first portion; providing a second portion; providing a third portion; permanently attaching the first portion to the second portion along an upper surface of the first portion; and permanently attaching the first portion to the third portion along a lower extent of the first portion. Attached Figure Description

[0009] Figure 1 This is a left front perspective view of the vehicle of the present invention without body panels;

[0010] Figure 2 yes Figure 1 The right rear perspective view of the vehicle;

[0011] Figure 3 yes Figure 1 The left-side view of the vehicle;

[0012] Figure 4 yes Figure 1 The right-side view of the vehicle;

[0013] Figure 5 yes Figure 1 A top view of the vehicle;

[0014] Figure 6 yes Figure 1 A front view of the vehicle;

[0015] Figure 7 yes Figure 1 Rear view of the vehicle;

[0016] Figure 8 yes Figure 1 The left front perspective view of the vehicle's frame;

[0017] Figure 9 yes Figure 8 The right rear perspective of the frame shown;

[0018] Figure 10 This is a left front perspective view of the vehicle's front suspension;

[0019] Figure 11 This is a left-side view of the vehicle's front suspension;

[0020] Figure 12 It is similar to removing the frame. Figure 10 The view;

[0021] Figure 13 Is it like this? Figure 12 The rear perspective view of the suspension shown;

[0022] Figure 14 This is an enlarged view of the right front suspension;

[0023] Figure 15 yes Figure 14 A partially exploded view of the suspension;

[0024] Figure 16 A floating rotor design for vehicles is shown;

[0025] Figure 17 This is the left front perspective view of the removable front frame section;

[0026] Figure 18 yes Figure 19 A partial exploded view of the removable front frame section;

[0027] Figure 19 It was from Figure 18 Left front perspective view of the final drivetrain after the front frame has been removed;

[0028] Figure 20 This is a bottom view of the vehicle showing the rear suspension;

[0029] Figure 21 This is a right front perspective view of part of the rear suspension;

[0030] Figure 22 It shows Figure 21 Exploded view of the rear suspension;

[0031] Figure 23 This is a front left perspective view of the vehicle's powertrain;

[0032] Figure 24 This is a right rear perspective view of the engine;

[0033] Figure 25 This is a right rear perspective view of the engine oil pan and lubrication system;

[0034] Figure 26 It is similar to Figure 25 The view shows the front return pump away from the oil pan decomposition;

[0035] Figure 27 Is it through Figure 25 Cross-sectional view of line 27-27;

[0036] Figure 28 Is it through Figure 25 A cross-sectional view of line 28-28;

[0037] Figure 29 This is a left-hand side view of the engine mount;

[0038] Figure 30 This is the left rear perspective view of the engine mount;

[0039] Figure 31 Similar to Figure 30 The engine and engine mount are shown in a disassembled manner, away from the frame;

[0040] Figure 32 This is the right-hand side view of the engine mount;

[0041] Figure 33 This is the right rear perspective view of the engine mount;

[0042] Figure 34 This is a left front perspective view of the transmission connected to the front final drive;

[0043] Figure 35 yes Figure 34 The rear perspective view of the transmission shown;

[0044] Figure 36 Is it through Figure 34 A cross-sectional view of line 36-36;

[0045] Figure 37 This is an exploded view of the slipper clutch section of the transmission;

[0046] Figure 38 A flowchart illustrating the torque control model is shown.

[0047] Figure 39 yes Figure 23 A front perspective view of the continuously variable transmission (CVT) of the powertrain shown;

[0048] Figure 40 This shows the internal housing of the CVT with the drive and driven clutches removed;

[0049] Figure 41 Is it through Figure 39 Cross-sectional view of line 41-41;

[0050] Figure 42 A coolant level switch for a coolant bottle is shown;

[0051] Figure 43 This is a front perspective view of the vehicle's universal bed;

[0052] Figure 44 A right-side view of the passenger seat and fuel tank configuration is shown;

[0053] Figure 45 It shows Figure 44 A top view of the seat shown;

[0054] Figure 46 An enlarged view of the rear cab frame support area is shown;

[0055] Figure 47 yes Figure 46 An incomplete enlarged view of the right rear part of the cab frame support area shown in the diagram;

[0056] Figure 48 Is it through Figure 46 A cross-sectional view of line 48-48;

[0057] Figure 49 This is a view showing the fully assembled tapered lock fittings;

[0058] Figure 50 The enlarged version is shown. Figure 46 The area indicated in the middle;

[0059] Figure 51 It shows Figure 17 Left front perspective view of the replaceable front frame section that can be removed;

[0060] Figure 52 yes Figure 51 A partially exploded view of the front frame section;

[0061] Figure 53 From Figure 51 Left front perspective view of the final drivetrain after the removal of the front frame section;

[0062] Figure 54 yes Figure 53 Left side view of the front frame section;

[0063] Figure 55 yes Figure 53 Right side view of the front frame section;

[0064] Figure 56 yes Figure 1 Left front perspective view of the vehicle's replaceable frame;

[0065] Figure 56A yes Figure 56 The left front perspective of a portion of the frame;

[0066] Figure 57 yes Figure 56 The right rear perspective of the frame;

[0067] Figure 58 It is connected to the replaceable cab frame. Figure 56 The left front perspective of the frame;

[0068] Figure 59 yes Figure 56 Detailed perspective view of the bolting components of the frame;

[0069] Figure 60 yes Figure 57 Detailed perspective view of the bolting components of the frame;

[0070] Figure 61 yes Figure 58 Left front perspective view of the cab frame;

[0071] Figure 62 yes Figure 61 Left rear perspective view of the bottom side of the cab frame;

[0072] Figure 63It is constructed to support the general-purpose bed, is part of the air inlet, part of the exhaust outlet, and part of the cooling system. Figure 57 Left rear perspective view of the support area at the rear of the frame;

[0073] Figure 64 yes Figure 63 Left rear perspective view of the support area;

[0074] Figure 65 yes Figure 64 A breakdown diagram of the support region;

[0075] Figure 66 yes Figure 63 Left rear perspective view of the bottom side of the support area;

[0076] Figure 67 yes Figure 66 Right rear perspective view of the bottom side of the support area;

[0077] Figure 68 yes Figure 67 A breakdown diagram of the support region;

[0078] Figure 69 yes Figure 1 A left front perspective view of a portion of the vehicle's replaceable front suspension.

[0079] Figure 70 yes Figure 69 Exploded view of the lower part of the linear force element of the front suspension and the U-shaped clamp of the linear force element;

[0080] Figure 71 yes Figure 1 Right rear perspective view of the vehicle's replaceable front braking system;

[0081] Figure 72 yes Figure 71 Left front perspective view of the brake disc and brake caliper of the front braking system;

[0082] Figure 73 yes Figure 72 An exploded view of the brake caliper and brake pads of the front braking system;

[0083] Figure 74 yes Figure 1 Right rear perspective view of the vehicle's replaceable rear braking system;

[0084] Figure 75 yes Figure 1 Left front perspective view of the vehicle's replaceable rear suspension;

[0085] Figure 76A yes Figure 75 Left front perspective view of the toe linkage coupling of the rear suspension;

[0086] Figure 76B yes Figure 76A Exploded view of a toe-type connecting rod coupling;

[0087] Figure 76C It is along Figure 76A The line cut from 76C-76C Figure 76A Cross-sectional view of a toe-type connecting rod coupling;

[0088] Figure 77A yes Figure 75 Left front perspective view of the trailing arm of the rear suspension;

[0089] Figure 77B yes Figure 77A Exploded view of the trailing arm;

[0090] Figure 78 It is along Figure 77A The line cut off at 78-78 Figure 77A Cross-sectional view of the trailing arm;

[0091] Figure 79 yes Figure 1 A perspective view of the arc spring assembly of the vehicle's powertrain;

[0092] Figure 80 It is connected to Figure 79 A perspective view of the crankshaft arc spring assembly of the powertrain engine;

[0093] Figure 81 yes Figure 79 Exploded view of the arc spring assembly;

[0094] Figure 82 yes Figure 79 A perspective view of the arc spring damping assembly;

[0095] Figure 83 It is along Figure 82 The line 83-83 was cut off Figure 82 Cross-sectional view of the arc-shaped spring damping assembly;

[0096] Figure 84 It is along Figure 82 The line 84-84 was cut off Figure 82 Cross-sectional view of the arc-shaped spring damping assembly;

[0097] Figure 85 yes Figure 56 Left front perspective view of the frame's front drive and mounting components;

[0098] Figure 86A yes Figure 85 Exploded view of the front drive and mounting components;

[0099] Figure 86B yes Figure 85 Right rear perspective view of the front drive and mounting components;

[0100] Figure 87A yes Figure 57 Left front perspective view of the rear drive and mounting components of the frame;

[0101] Figure 87B yes Figure 87A Exploded view of the rear drive and mounting components;

[0102] Figure 88 yes Figure 1 A perspective view of the vent pipe of the vehicle's powertrain;

[0103] Figure 89 yes Figure 88 A further perspective view of the ventilation tube;

[0104] Figure 90 It is along Figure 88 The line is cut at 90-90 degrees. Figure 88 A cross-sectional view of a portion of the ventilator;

[0105] Figure 91 yes Figure 89 An exploded view of the ventilator;

[0106] Figure 92 Is when Figure 1 When the vehicle is in a flipped or overturned state Figure 89 A cross-sectional view of the check valve on the vent pipe;

[0107] Figure 93 Is when Figure 1 When the vehicle is in an upright position on the ground surface Figure 92 A cross-sectional view of the check valve;

[0108] Figure 94 yes Figure 1 The right rear perspective view of the vehicle's air intake baffle;

[0109] Figure 95 yes Figure 94 A perspective view of the air intake baffle;

[0110] Figure 96 This is an exploded view of the air intake baffle and baffle cover;

[0111] Figure 97 yes Figure 1 The right rear perspective view of the vehicle's exhaust outlet;

[0112] Figure 98 yes Figure 97 Right rear perspective view of the muffler at the exhaust outlet;

[0113] Figure 99 It is along Figure 98 A cross-sectional view of the exhaust port outlet section taken from line 99-99;

[0114] Figure 100 yes Figure 1 A perspective view of the vehicle's coolant bottles;

[0115] Figure 101 yes Figure 57 Left rear perspective view of the frame and fuel tank with ventilation ducts;

[0116] Figure 102 It is used for Figure 1 Rear right perspective view of the shift assembly of a vehicle's gearbox capable of shifting gears;

[0117] Figure 103 yes Figure 102 An elevation view of the shift assembly and a portion of the transmission capable of shifting gears;

[0118] Figure 104 yes Figure 1 A left front perspective view of the panels within the seating area of ​​the vehicle;

[0119] Figure 105 yes Figure 104 Exploded view of the sheet metal;

[0120] Figure 106 yes Figure 1 A perspective view of the vehicle's air intake grille and part of the hood;

[0121] Figure 107 yes Figure 106 Bottom side view of the hood and air intake grille;

[0122] Figure 108 yes Figure 107 An exploded view of the hood and grille;

[0123] Figure 109 This is a perspective view of the air intake grille and hinge assembly;

[0124] Figure 110 yes Figure 109 Further perspective view of the air intake grille and hinge assembly;

[0125] Figure 111 yes Figure 110 Another perspective view of the air intake grille and hinge assembly;

[0126] Figure 112 It is connected to Figure 1 Right front perspective view of a light bar assembly, part of the cab frame of the vehicle.

[0127] Figure 113 It is to install the light strip assembly to Figure 112 A perspective view of the cab frame;

[0128] Figure 114 yes Figure 112 A perspective view of the bottom side of the mounting components of the light strip assembly;

[0129] Figure 115 yes Figure 12 Rear perspective view of the lower suspension arm;

[0130] Figure 116 yes Figure 115 Front perspective view of the lower suspension arm;

[0131] Figure 117A yes Figure 116 Exploded view of the lower suspension arm;

[0132] Figure 117B yes Figure 117A A further exploded view of the lower suspension arm;

[0133] Figure 118 yes Figure 115 A perspective view of the ball joint housing of the lower suspension arm;

[0134] Figure 119 It is along Figure 116 The line 119-119 was cut off. Figure 116 Cross-sectional view of the lower suspension arm;

[0135] Figure 120 It is along Figure 116 The line was cut at 120-120. Figure 116 Cross-sectional view of the lower suspension arm;

[0136] Figure 121 It is connected to the one used for Figure 12 The U-shaped clamp of the linear force element in the suspension assembly Figure 116 Front perspective view of the lower suspension arm;

[0137] Figure 122 yes Figure 121 Exploded view of the lower suspension arm and U-shaped clamp;

[0138] Figure 123 yes Figure 122 A perspective view of the U-shaped clip;

[0139] Figure 124 yes Figure 116 Front view of the lower suspension arm and Figure 123 A cross-sectional view of the U-shaped clamp, showing the U-shaped clamp relative to the axle or half-axle during operation when the vehicle is at driving height;

[0140] Figure 125 yes Figure 116 Front view of the lower suspension arm and Figure 123 A cross-sectional view of the U-shaped clamp, showing the U-shaped clamp relative to the axle or half-shaft during operation of the vehicle in full rebound of the suspension assembly;

[0141] Figure 126 yes Figure 12 A perspective view of the upper suspension arm of the suspension assembly. Detailed Implementation

[0142] Will first refer to Figures 1 to 7 The vehicle of the present invention is described. As shown in the figure, the vehicle as a whole is depicted with reference numeral 2, including a front wheel 4 and a rear wheel 6. The front wheel 4 is composed of a rim 8 and a tire 10, and the wheel 6 is composed of a rim 14 and a tire 16. The wheels 4 and 6 support the vehicle frame, the vehicle frame as a whole is shown at 20 (…). Figure 3 The cab frame, shown at 28, supports the seating area 22 comprised of the driver's seat 24 and the passenger seat 26. It extends substantially over the seating area 22 to protect passengers from objects such as tree branches. Passenger grab bars 32 are provided for passengers in seat 26. Figure 2 As best shown, vehicle 2 further includes a steering assembly at 34 to steer the front wheels 4, wherein the steering assembly 34 includes a steering wheel 36 that is both tiltable and longitudinally movable, as described in U.S. Provisional Patent Application No. 62 / 615,684, filed January 10, 2018, the subject of which is disclosed herein in its entirety.

[0143] Vehicle 2 further includes a front suspension 40, which, in this disclosure, is a double A-arm suspension, and vehicle 2 further includes a rear suspension 42, which, as shown in this disclosure, is a trailing arm suspension. Figures 2 to 4 The best shown in the middle (see also) Figure 22 The powertrain consists of an engine 50 ( Figure 3 ), Continuously Variable Transmission (CVT) 52 ( Figure 3 ) and the 56-speed transmission capable of shifting gears. Figure 3 The transmission 56, capable of shifting gears, can be composed of a shift assembly 60. Figure 5 ) operation. In a preferred embodiment of the invention, the vehicle is a four-wheel drive vehicle, including a front final drive 70 ( Figure 2 It has a front short axle 72 that is connected to the front final drive 70 to drive the front wheels 4. The rear final drive 76 ( Figure 2 , Figure 7The vehicle is configured to drive half-shaft 78, which drives the rear wheels 6. As shown, vehicle 2 also includes an exterior body 80, which includes a hood 82, side panels 84, doors 86, a general-purpose bed 88, and a rear panel 90. The vehicle described herein may be further constructed as shown in U.S. Patent No. 8,827,028 and / or U.S. Patent Application No. 62 / 615,684, the subject of which is disclosed herein in its entirety.

[0144] Now for reference Figures 8 to 9 Framework 20 will be described in more detail. First, refer to... Figure 8 The frame 20 is composed of an outer frame tube 100 and an inner frame tube 102. The outer frame tube 100 includes a longitudinally extending portion 104 and a vertically extending portion 106. The frame tube 102 includes a longitudinally extending portion 108 and a vertically upright frame tube 110. The outer frame tube 112 extends forward and is generally parallel to the frame tube 104 and connects to the upright frame tube 114. The frame tube 114 supports a U-shaped frame tube 116 with a connector 118 to which the cab frame 28 is attached. The U-shaped tube 116 is supported by a front frame portion 120, which is composed of a fixed front frame portion 122 and a movable front frame portion 124. The fixed front frame portion 122 is composed of three sets of upwardly extending frame tubes, namely frame tubes 126, 128, and 130. The fixed frame portion also includes transverse frame members 132 and 134. Figure 9 Finally, the fixed front frame portion 122 is composed of longitudinal tube portions 140.

[0145] Still referencing Figure 8 The seat support, shown as 150, includes transverse frame tubes 152 and 154, a pair of longitudinal frame tubes 156 supporting seat 24, and frame guide rails 158 for supporting seat 26. Now refer to... Figure 9 This will describe the latter part of frame 20.

[0146] refer to Figure 9 The powertrain support region 170 is configured to include a rearwardly extending frame tube 172 and an upwardly extending frame tube 174. The frame tube 174 extends upward and includes a forward-projecting tube portion 174a and a vertically extending portion 174b.

[0147] Now for reference Figure 9The cab frame support area 180 is configured with a transverse tube at 182, which connects to a forward-projecting tube portion 174a of the frame tube 174. The transverse tube 182 also connects to frame tubes 106 and 184. A tapering joint bracket 186 connects to the frame tube 182, as described further herein. A frame tube 190 extends upward from tube 174a and includes a bracket 196 to which the rear portion of the cab frame 28 connects, as described further herein.

[0148] Now for reference Figure 8 and Figure 9 The general-purpose bed support area 200 will be described in more detail below. Support area 200 includes a transverse tube 202 that extends between tubes 106 and is supported by an upright frame tube 110. A rear transverse tube 206 extends transversely to and connects to frame tube 174. Support area 200 further includes a longitudinally extending tube 208 that connects rearward to tube 206 and at its front end to a support 210.

[0149] Still referencing Figure 8 and Figure 9 The door support brackets are installed on the driver's side and the passenger side, whereby brackets 224 and 226 extend forward from tube 106 on the driver's side, and brackets 224 and 228 extend forward on the passenger side.

[0150] Finally, and still about Figure 8 and Figure 9 This will describe the engine mount bracket. For example... Figure 8 As shown, the left-hand side frame assembly is shown at 240, and the right-hand side frame assembly is shown at... Figure 9 It is shown at position 242. Also... Figure 9 244 and 246 in the diagram show the left-hand side support and the right-hand side support.

[0151] Now for reference Figures 10 to 15 The front suspension will be described in more detail. For example... Figure 10 As shown, frame 20 includes upper couplings 260, 262 and lower couplings 264, 266. Rear couplings 268 and 270 are also provided for the left-hand side front suspension 40. Figure 11 A mirror coupling is provided for the right-hand side suspension 40. Suspension 40 includes an upper A-arm 280, a lower A-arm 282, and a linear force element (LFE) 284, which is shown as a damping spring. A front final drive 70 is shown located between front couplings 260-266, wherein a half-shaft 290 extends from the front final drive 70 to drive wheel hub 292. The damper 284 is coupled to the frame at the upper bracket 296 and to the lower A-arm 282 via a U-clamp 298 that positions the half-shaft 290 between its two wings, as described in more detail herein.

[0152] The front suspension 40 further includes a stabilizer or torsion bar 300, which is coupled to the frame tube 128 and to the lower A-arm 282, as further described herein. Figure 12 and Figure 13 As shown, the torsion bar 300 includes a transverse bar 302, which is connected to a linkage arm 304, which in turn is connected to a bar 306. The bar 306 is connected to a bracket 308 positioned on the lower A-arm 282. Figure 14 and Figure 15 As shown, the bracket 282 is composed of plates 310 and 312, which have through holes 314 and 316 to receive fasteners 320 passing through these holes. Figure 12 ).like Figure 15 As best shown, the lower A-arm 282 includes a shock-absorbing mounting bracket 330 having an orifice at 332. A sleeve 334 is received in the orifice 332 from one side, and a bearing 336 is received on the opposite side of the orifice 332 and held in place by a retaining ring 338. A second sleeve 340 is positioned within the orifice 332, thereby allowing a fastener 342 to be received through the sleeve 334, bearing 336, and sleeve 340, thereby engaging the fastener 344 to secure the U-shaped clip 298. Figure 15 As best shown, the U-clamp 298 includes U-clamp legs 350, each having an opening at 352 to receive a fastener 342 passing through the opening. The legs 350 of the U-clamp 298 extend vertically to allow free movement of the half-shaft 290 within the U-clamp 298 during suspension operation. An axis 354 extending downward along the axial center of the damping member intersects the half-shaft 290.

[0153] Now for reference Figures 12 to 15 Each of the control arms 280 and 282 is connected to the frame via couplings 370, 372, 374, and 376 and external couplings 380, 382, ​​384, and 386. It should be understood that the A-arms 280 and 282 are connected to the frame via couplings 260-270 on the frame, as described above and as... Figure 10-11 As shown in the diagram, the outer ends of the A-arms 280 and 282 are fixed to the steering spindle 390 via upper and lower ball joints 392 and 394. Figure 13As best shown herein, the steering spindle 390 includes a steering link 398, to which a steering arm 400 is attached via a ball joint 402. The steering arm 400 is coupled at its inner end to a steering motor 410 having an input at 412, which is coupled to the steering system 34 to rotate the left and right front wheels 4 via a steering rack 414. The steering spindle 390 rotates about an axis passing through the ball joints 392 and 394, while simultaneously securing the wheel hub 292 and the front braking system 420 to the steering spindle 390, as described in more detail herein.

[0154] Now for reference Figure 16 The front braking system 420 will be described in more detail below. As shown, the braking system 420 is coupled to the steering spindle 390 and includes a brake caliper 422, a disc 424, and a brake disc 426. As shown, the hub 292 includes an inner hub portion 292a and an outer hub portion 292b. The inner hub portion 292a is directly coupled to the half-shaft 290 for being driven, and the hub portion 292a includes a plurality of fasteners 428. The hub portion 292b includes a plurality of orifices at 430 that receive fasteners 432 passing through them, and the brake disc 426 includes orifices 436. The hub portion 292b includes a plurality of orifices 440 that are aligned with the fasteners 428, such that the hub portion 292b and the brake disc 426 are directly coupled to the hub portion 292a. The caliper 422 and the disc 424 are coupled to the brake bracket at 422, such that the disc 422 is held on opposite sides of the brake disc 426. Alternatively, the brake disc may be shown as a single component, comprising brake disc 426, hub 292b, and fastener 432. Furthermore, fastener 432 may be a rivet, such as a countersunk rivet.

[0155] Now for reference Figures 17 to 19 The removable front frame portion 124 will be described in more detail. For example... Figure 17 and Figure 18 As shown, the removable front frame portion 124 is coupled to a frame just adjacent to suspension couplings 260, 262, 264, and 266. The removable front frame portion 124 includes a plate segment 450 with a bracket 452 mounted thereon, which provides positioning for the winch frame. A tow bar 454 is mounted to the bracket 452, and a hook 456 is mounted on the lower portion of the plate portion 450. The plate portion 450 includes four mounting holes at 458 that provide passage for fasteners 460. Each of the holes 458 further includes a positioning hole 464 as further described herein.

[0156] As shown in the figure, the fixed frame portion 122 includes an upper frame tube portion 470 that is substantially parallel to the lower frame tube 102. Each of the upper frame tube 470 and the lower frame tube 102 includes inserts 480, 482, 484, and 486. As shown, each of the couplings 480-486 performs two functions: firstly, defining a portion of the suspension couplings 260-266, and secondly, providing a mounting position for the removable frame portion 124. More specifically, the insert 480 includes a cylindrical portion 480a to which a support arm 480b is mounted. The cylindrical portion has an orifice defining the mounting position for the upper A-arm 280. The insert 480 also includes a raised flat block 480c, which is teardrop-shaped and has a threaded orifice at 480d and a locating lug at 480e. In a similar manner, the insert 482 includes a cylindrical portion 482a, a plate 482b, a raised flat block 482c, a threaded hole 482d, and a positioning lug 482e.

[0157] like Figure 19 As shown, insert 484 includes a cylindrical portion 484a, a plate portion 484b, a raised flat block 484c, a threaded orifice 484d, and a locating lug 484e. Similarly, insert 486 includes a cylindrical portion 486a, a plate portion 486b, a raised flat block 486c, a threaded orifice 486d, and a locating lug 486e. It should be understood that each of the cylindrical portions 480a, 482a, 484a, and 486a includes a diameter-reducing portion extending rearward therefrom, which can be received into the corresponding frame tube 102 or 470, thereby allowing inserts 480-486 to be held in place by industrial adhesives or other bonding methods such as welding.

[0158] pass Figure 18 and Figure 19 It should be noted that the flat blocks 480c-486c provide interfaces for attaching the removable frame portion 124 to the fixed frame portion 122. Specifically, each orifice 458 and the movable frame portion 120 aligns with the associated threaded portions 480d-486d, and each alignment orifice 464 aligns with the corresponding locating lugs 480e-486e. Thus, once aligned, the fastener 460 can be received through the corresponding orifice 458 and enter its corresponding threaded orifice 480d-486d. To remove the front final drive 76, the removable front frame portion 124 is simply removed by disengaging the fastener 460, thereby allowing the removable front frame portion 124 to move... Figure 18 As shown in the figure, the front final drive 76 can be removed by separating fasteners 490 and 492 (Figure).

[0159] pass Figure 19It should be noted that since couplings 260-266 remain fixed to the fixed frame portion 124, removing the removable frame portion 124 and the front final drive 76 does not require removing the front suspension 40. It should also be noted that the front final drive 76 includes a mounting insert 496, which is engaged with fastener 490 in a manner substantially as shown in U.S. Patent Application No. 15 / 389,147, the subject matter of which is incorporated herein by reference.

[0160] In addition, the upper couplings 260 and 262 serve two functions. First, each coupling 260 and 262 provides the mounting structure for the front suspension as described above, but also includes sidewalls 260a and 262a (…). Figure 19 The sidewall includes an opening for receiving fastener 490.

[0161] Now for reference Figures 20 to 22 The rear suspension 42 will be described in more detail. Figure 20 The rear suspension 42 is shown from the bottom side of the rear suspension in the best view, in relation to the engine 50, CVT 52, and shiftable transmission 56. As shown, the CVT 52 is positioned in front of the support area 200 and occupies space largely occupied by the torsion bar. The rear suspension 42 includes a pair of trailing arms 500, which are coupled to the frame at their front ends. Figure 3 Thus, the trailing arm rotates around axis 502. Figure 3 The radius arm 506 is connected to the frame 20 at the inner end 508 and to the tow arm 500 at the outer end.

[0162] Now for reference Figure 21 and Figure 22 The torsion bar assembly will be described in more detail below. As shown in the figure, the upper side of the trailing arm includes a bracket 512 for mounting the torsion bar assembly 510 and a bracket 514 for mounting the rear linear force element 516. Figure 1 As shown in the figure, the torsion bar assembly 510 is connected to the same bracket 210 as the mounting frame tube 208. Figure 2 ), 210 bracket supports universal bed 88 ( Figure 2 The bracket 210 includes a bracket portion 210a for mounting the tube 208 and a bracket portion 210b facing rearward and downward for mounting the torsion bar assembly 510. The torsion bar assembly 510 includes a transverse bar portion 520 to which a link arm 522 is fixedly mounted. The link arm 522 is connected to a link 524, which in turn is connected to the bracket 512. The torsion bar assembly 510 may be further constructed as shown in U.S. Patent No. 8,827,019, the subject matter of which is incorporated herein by reference.

[0163] Now for reference Figure 21 and Figure 22The torsion bar assembly 510 includes a bearing 530 having a bearing half 532 and bearing races 534. The bearing half 532 is divided to receive a reduced-diameter segment 540 in a rotatable manner and is received within each race 534. Each race 534 includes an aperture at 544 that receives a fastener 546 passing through it. The fastener 546 extends through an aperture 548 in the support portion 210b to connect the transverse portion 520 to the frame tube 210. The link arm 522 has a split opening at 550 that connects to the end 552 of the transverse portion 520. The split portion 550 includes an aperture at 556 that receives a fastener 558 to clamp the split opening 550 to the portion 552. The link arm 522 includes a connector 560 at opposite ends that corresponds to a coupling 562 of the link 524. Fastener 564 can be received by connectors 560 and 562 and secured by anti-fastener 566. The lower end of link 524 also includes a lower connector at 568, which receives fastener 570 passing through it, thereby connecting link arm 524 to bracket 512 with anti-fastener 572.

[0164] Refer again Figure 20 It should be noted that the suspension, specifically the radius rod 506, is centered on the vehicle's longitudinal centerline 580, while the engine's centerline offsets from the vehicle's longitudinal centerline at centerline 582. Due to this offset of the engine 50, the transmissions to the front final drive 70 and the rear final drive 76 are at a slight angle. More specifically, as... Figure 20 As shown, the rear support shaft 586 extends at a slightly skewed angle 588, while the front support shaft 590 extends at a slightly skewed angle 592. (See again...) Figure 11 The front support shaft 590 includes a coupling at 594, which may be in the form of a universal joint. The universal joint includes a front coupling at 596, which is guided upwards to the front final drive 70. The steering gear 414 is positioned as low as possible within the vehicle and is located in the area defined by the angle between the front support shaft 590 and the front coupling 596. This optimizes bump steering.

[0165] Now for reference Figures 23 to 28 The front return oil pump of engine 50 will be described in more detail. For example... Figure 23 As shown, engine 50 drives CVT 52, which in turn drives shiftable transmission 56. Shiftable transmission 56 is coupled to support shafts 586 and 590 to drive rear final drive 76 and front final drive 70, respectively. It should be understood that engine 50 is substantially the same as in U.S. Patent Applications Nos. 15 / 595,224 and 15 / 595,209, the subject matter of which is incorporated herein by reference.

[0166] like Figure 24 As shown, engine 50 includes engine block 600, valve cover 602, oil pan 604, oil filter system 606, and intake system 608. Timing chain cover 610 surrounds the engine's camshaft chain and also surrounds... Figure 25 The auxiliary return oil pump 612 is shown. Figure 25 and Figure 26 As shown, pump 612 includes an integrated pump housing 614 within an oil pan 604, the integrated pump housing 614 including an inlet region 620 and a discharge region 622. The housing portion 614 includes a circular opening at 624 to receive the outer rotor 626 and inner rotor 628 of the return pump. A drive coupling 630 is provided, which is connected at one end to the main oil pump 652 via a rectangular drive 632 and at the opposite end to a drive gear 634 via a truncated circular portion 636 corresponding to a similar opening at 638 of the gear 634. A pin 639 is positioned in an orifice 630a and received in a slot 628a to drive the internal gear pump 628.

[0167] Cover 640 is configured with an opening at 642, which receives a siphon screen at 644, corresponding to the opening at 620. As should be understood from the previous description of the powertrain, the cam chain oil pump 612 is longitudinally positioned at the rear of the vehicle, such that during extreme tilting of the vehicle, oil flows to the cam chain region 646, which draws oil from the main oil sump 648 (…). Figure 25 Take it away. Therefore, as Figure 27 As shown, the drive chain is connected to gear 634, drives internal gear pump 628 via pin 639, and drives pump shaft 650 of main oil pump 652 via rectangular end 632. Figure 28 As shown, oil moves into inlet 644 in the direction of the arrow, whereby the internal gear pump 628 causes the oil to move in the direction of the arrow 660 and upward in the direction of the arrow 662, leaving the cam chain area 646 and returning to the main oil tank area 648.

[0168] Now for reference Figures 29 to 33 The mounting of engine 50 within frame 20 will be described in more detail. First, as... Figures 29 to 31 As shown, the left-hand side frame assembly 240 is shown attached to the engine 50. As illustrated, the frame assembly 240 includes a removable frame 670. Figure 31The left-hand side frame assembly 240 is defined by a channel-shaped member having a parallel plate portion 672, which defines an upper platform at 674. The front edge of the plate portion 672 includes an aperture 676, and the rear edge defines an aperture 678. Brackets 680 and 682 define apertures 684 and 686, respectively, which are aligned with apertures 676 and 678. Fastener 688 can be received through apertures 676 and 684, while fastener 690 can be received through apertures 678 and 686. Anti-fastener 692 engages with fasteners 688 and 690 to secure the left-hand side frame assembly 240 to the frame 20.

[0169] like Figure 31 As shown, a mounting bracket is illustrated at 700, which is attached to the rear side of the transmission 56 and the left side of the engine 50, as shown. Figure 29 and Figure 30 As shown in the diagram. The bracket 700 is somewhat L-shaped, having a lateral support leg at 702 and a longitudinal support leg at 704. Support leg 702 includes an aperture at 706, while support leg 704 has an aperture at 708. Aperture 706 is aligned with aperture 710 on the rear side of the transmission 56, and aperture 708 is aligned with aperture 712 (see [reference]). Figure 23 Fastener 714 (see...) Figure 29 It can be received through orifice 708 and threadedly engaged with orifice 712 (see...). Figure 23 Fastener 716 is received through orifice 706 and threadedly engaged with orifice 710. A spacer 720 is provided to engage between brackets 670 and 700. The spacer 720 includes a lower portion 722 that receives fastener 724 passing through it and is capable of receiving fastener 724 through a threaded orifice 728 of bracket 670. The spacer 720 further includes an arcuate flange 730 having an orifice at 732. A complementary arcuate flange 740 is positioned on bracket 700 having a threaded orifice at 742. Thus, fastener 744 is received through orifice 732 and threadedly engaged with orifice 742.

[0170] Still referencing Figure 31 The diagram shows a retainer 750, which is substantially similar to a frame 720, having a lower frame portion at 752 and an arcuate flange at 754, the arcuate flange 754 having an aperture 756. A bracket 244 includes a threaded aperture at 758, which receives a fastener 760 passing through it and through the frame 752 to secure the frame 750 to the bracket 244. The transmission 56 also includes an arcuate flange at 770 (see also...). Figure 34 The arcuate flange 770 has a threaded orifice at 772. A fastener 774 can be received through orifice 756 and threaded into orifice 772 of the transmission 56. The arcuate flange 770 is located at... Figure 23This is further evident in the text. From... Figure 30 It should be noted that the bracket 670 is positioned adjacent to the support shaft 586 such that the removal of the bracket 670 and the spacer 720 provides full access to the support shaft 586 for removal and / or replacement.

[0171] Now for reference Figure 32 and Figure 33 The right-hand side engine mount will be described in more detail. As shown, the right-hand side mount assembly 242 has an upper platform 790 that receives the isolating mount 792 in a manner similar to that of the mount 720. The bracket 794 passes through an access port 798 (see...). Figure 24 Fastener 796 is attached to the right-hand side of the engine. Fastener 800 attaches the isolator to bracket 794. Further details of the isolator can be found in U.S. Patent No. 9,873,316, the subject matter of which is incorporated herein by reference.

[0172] Now for reference Figures 34 to 38 This will describe the torque control characteristics of the transmission in more detail. First, refer to... Figure 34 The diagram shows a transmission 56, which includes a transmission housing at 820, the transmission housing 820 having an engine interface at 822. Figure 35 The engine interface 822 defines a flange for mounting the engine 50. The intermediate shaft 824 is configured to have an input at 826 and an output at 828. The transmission 56's drive mechanism is located within the housing 830 and is driven via the input shaft 832. It should be understood that the CVT 52 ( Figure 23 A drive shaft 824 is connected between shafts 828 and 832, allowing the engine 50 to drive the intermediate shaft 824. Shaft 828 drives the transmission pulley within the CVT 52, and the driven pulley of the CVT 52 drives the input shaft 832 of the transmission 56. Figure 34 As shown, the output shaft of the transmission 56 is also located at 840, and the output shaft 840 has a shaft portion 842 connected to the front support shaft 590 and a portion connected to the rear support shaft 586. Figure 23 The rear output shaft 844.

[0173] Now for reference Figure 36 and Figure 37A slip clutch is defined between shaft portions 842 and 844 to limit torque through the front support shaft 590. As shown, the slip clutch is defined by a plurality of friction discs 850 inserted between a plurality of clutch discs 852. The friction discs 850 include a plurality of discs with friction surfaces 854 of a material such as carbon fiber or graphite, thereby causing frictional engagement between the friction discs 850 and the clutch discs 852. Each of the friction discs 850 includes teeth at 858, while the clutch discs 852 include splines 860. Shaft portion 842 includes a diameter-reduced portion 868 having a splined portion at 870, a diameter-enlarged portion at 872, a fixed pressure plate at 874, and a splined segment at 876. Shaft portion 842 further includes a threaded shaft portion 880 and a diameter-reduced portion 882.

[0174] The shaft portion 844 includes a splined output shaft at 890, an enlarged diameter portion at 892, and a basket 894 with multiple teeth 896 that mesh with teeth 858 of the friction disk 850. The shaft portion 844 further includes a helical gear 898, which is driven by the input of the lower shaft 840 via shaft 832. The slip clutch further includes a wave spring 900, a pressure nut 902, a movable pressure plate 904, a timing disc 906, bearings 908 and 910, and seals 912 and 914.

[0175] Multiple friction discs 850 and clutch discs 852 are slidably received on the splined shaft portion 876, with the splines 860 of the clutch disc aligned with the splines of the splined portion 876. This positions the multiple stacked discs 850, 852 against the inner surface of the fixed pressure plate 874, as shown below. Figure 36 As best shown in the diagram. Then, a movable pressure plate 904 is received on the spline portion 876 to be positioned against the last of the friction discs 850. Next, a wave spring 900 is positioned on the shaft portion 880 to be positioned against the pressure plate 904, and a pressure nut 902 is threadedly received on the shaft portion 880 and twisted to a preset torque, wherein the wave spring presses against the pressure plate 904, as... Figure 36 The best example shown is...

[0176] like Figure 36As shown, the idler shaft 920 provides a helical gear 922 that engages with the helical gear 898. Shaft 920 is drivably coupled to input shaft 832, such that input torque from the engine is transmitted via CVT 52 to transmission 56 and to outputs 842 and 844. However, when the torque at 844 reaches a preset maximum torque, which is the torque at which friction disc 850 and clutch disc 852 begin to slide relative to each other, the torque through shaft 842 is limited by a slip clutch defined by discs 850 and 852. It should be noted that as friction disc 850 is rotatably fixed relative to shaft 844, clutch disc 852 is rotatably fixed relative to shaft 842. When the torque at output shaft 844 is below a threshold torque, the entire shaft 840 rotates as a single piece. However, when the torque exceeds the predetermined maximum torque, discs 850 and 852 slide relative to each other, allowing different rotational speeds between shafts 842 and 844. (See again) Figure 36 The rotational speed of the shaft 842 is measured by the timing gear 906, which includes a plurality of timing teeth 930 and a timing sensor is positioned in the orifice 932. Figure 37 The speed of shaft 842 is calculated by counting the rotation of the sharp teeth.

[0177] Therefore, refer to Figure 38 A torque model can be provided using multiple sensed circumferences, calculated circumferences, and output circumferences. The axial speed of the front axle portion 842 is determined at 940, the axial speed of the rear axle portion 844 is determined at 942, and the difference between the two axle portions 842 and 844 is determined at 944, so that the axial speed difference is defined at 948. Therefore, as described above, if the torque at axle portion 844 is lower than a predetermined maximum torque, the axial speed difference at 948 is 0. When the torque at axle portion 844 exceeds the predetermined maximum torque, disks 850 and 852 begin to slide to calculate the axial speed difference and input it into the torque model at 950, while the engine output torque is limited by the engine control unit at 952.

[0178] Now for reference Figures 39 to 41 The CVT 52 will be described in more detail below. As shown in the figure, the CVT 52 includes an inner housing 970 (adjacent to the engine 50 and transmission 56) and an outer housing 972. The CVT 52 will also include a drive side 974 and a driven side 976, and includes a drive clutch 978 and a driven clutch 980. Figure 41 The CVT 52 has a front air intake 982, a rear air intake 984, and an exhaust port 986. The CVT 52 may also be configured as shown in U.S. Patent Application No. 62 / 644,717, filed March 19, 2018, the subject matter of which is incorporated herein by reference.

[0179] Because engine 50 is not directly connected to CVT 52, but rather to engine interface 822 ( Figure 35 ), intermediate shaft 824, so output 828 passes through shaft housing 990 ( Figure 34 Extending outwards, the shaft housing 990 has a small profile in the radial direction. The shaft housing 990 also protrudes through the opening 992, as... Figure 40 and Figure 41 As best shown, this provides a large space 994 around the inner sleeve portion 996. The space 994 provides air volume, allowing a large amount of air to flow around the inner sleeve portion 996 and the outer sleeve portion 998 for cooling.

[0180] Now for reference Figure 42 The coolant bottle is shown at position 1000, and coolant bottle 1000 has an integrated switch to determine the coolant level.

[0181] Now for reference Figure 43 The diagram shows that the universal bed 88 includes a channel 1002 and a drain outlet 1004 to remove contaminants so that water is not drained onto the hot parts of the powertrain.

[0182] Now for reference Figure 44 and Figure 45 The fuel tank 1050 is shown located below and behind the passenger seat 26. As shown, the fuel tank 1050 includes a longitudinal extension at 1052, which is lower than and below the seat 26. The longitudinal end 1052 includes a fuel pump 1054 that draws fuel from the lowest part of the fuel tank 1050. The fuel tank 1050 also includes a vertical extension at 1060, which includes a stuffing tube at 1062. As shown, the vertical extension 1060 is located behind the passenger seat 26.

[0183] Now for reference Figures 1 to 5 and Figures 46 to 49 The cab frame 28 will be described in more detail. First, as... Figures 1 to 5 As shown, the cab frame 28 generally includes longitudinally extending frame members 1070 and 1072, which are coupled to couplers 1074 and 1076 at their front ends and to couplers (not shown) at their rear ends. Intermediate frame portions 1080 and 1082 extend downwards near the seats 24 and 26 and are coupled to coupler 1086. Referring now... Figures 46 to 49 The connector 1086 will be described in more detail. For example... Figure 47As shown, coupling 1086 includes a tapered lower portion 1090 at 1090, which extends along axis 1092, shared with the axis of coupling 186. The upper portion of coupling 1086 includes a collar 1094, which is offset relative to axis 1092 and includes an opening at 1096. Opening 1096 allows access to opening 1100, which extends through the tapered portion 1090 (see [reference]). Figure 48 ).

[0184] Coupling 186 includes a tapered portion 1102 that mates with a tapered portion 1090 and has a lower portion 1106 with an opening at 1108. An orifice 1110 provides passage between the opening 1108 and the tapered portion 1100 to receive a fastener such as 1114. A counter-fastener 1116 is positioned by a retaining portion 1112 in the opening 1096, which retains the fastener 116 and prevents rotation of the fastener 116. Thus, a connecting portion 1086 can be connected to the coupling 186 on the tube 182 by positioning the tapered portion 1090 within the coupling 186. This positions the tapered portion 1090 within the tapered portion 1102 of the coupling 186, as... Figure 48 As best shown in the diagram. Fastener 1114 is thus positioned through opening 1110, which positions the threaded portion within opening 1096 of coupling 1086. Fastener 1116 can then be threaded onto the threads of fastener 1114 to secure tube 1082 to tube 182. Alternatively, bracket 196 ( Figure 9 Alternatively, a gradually tapering coupling 186 can be used instead. Preferably, the axes 1092 of all the gradually tapering couplings 186 will be parallel.

[0185] Now for reference Figure 50 The diagram shows joint 1120, which provides connections to pipes 106 and 176 in a larger pipe 182. In this case, pipe 106 (involving a forked through-tube) is inserted through both walls of the larger diameter pipe 182, that is, through openings 1122 and 1124. This is a very efficient method for transferring bending moments and properly loading the segment, especially in welded space frame structures where multiple pipes share a common node.

[0186] Instead of not sharing multiple pipe nodes to maintain proper welding shelving, a forked yoke through-tube profile can be added to the laser-cut tube to achieve proper welding shelving, improve fatigue life, and eliminate welding fixture loading sequence issues. A reduction in total weld length is also required as a small cost benefit. Plastic packaging requires only approximately 270 degrees of wrapping around the tube. Also, as shown in the figure, the partially inserted tube 176 finds a natural stop against the punctured tube 106.

[0187] Now for reference Figures 51 to 55 The description can replace, for example Figures 17 to 19 The front frame shown is an alternative to the front frame. As shown, the front frame 1320 includes a front frame portion 1322 and a removable front bumper portion 1324. Figure 52 ).like Figure 52 As shown, the front frame 1322 generally consists of a lower longitudinal tube 1330, an upper longitudinal tube 1332, a front diaphragm plate 1334, and left and right side plates 1336 and 1338. Figure 53 )constitute.

[0188] like Figure 53 As best shown, the lower longitudinal tube 1330 includes a threaded insert 1340, while the upper longitudinal tube 1332 includes a threaded insert 1342. A front base plate 1334 is coupled to the lower longitudinal tube 1340 and the upper longitudinal tube 1342, and includes an opening 1350 that substantially mates with to allow the front drive 70 to pass through, as will be described in more detail herein. A side plate 1336 is substantially coupled to the left-hand side lower longitudinal tube 1330 and upper longitudinal tube 1332, as shown herein. Figure 54 As best shown in the diagram. The left panel 1336 includes an opening at 1360 to allow access between the front drivetrain 70 and the left front wheel. The left side panel 1336 further includes a front opening at 1362 and a rear opening at 1364, both aligned with the mounting insert 496. Figure 53 As further described herein, the front base 1370 is positioned below the orifice 1362, and the rear base 1372 is positioned below the opening 1364. Base 1370 defines a mounting surface at 1374, while base 1372 defines a mounting surface at 1376.

[0189] Now for reference Figure 55 The right-hand side plate 1338 connects to the lower longitudinal tube 1330 and the upper longitudinal tube 1332. Plate 1338 includes an opening at 1380, which is substantially the same as opening 1370 and allows access between the front wheel and the final drive 70. The right-hand plate 1338 also includes a forward aperture at 1382 and a rearward aperture at 1384. It should be noted that apertures 1382 and 1384 are aligned with the left-hand side plate 1336 via openings 1362 and 1364 respectively, and are visible through the left-hand side plate 1336, as shown. Figure 54 As shown in the image.

[0190] Refer again Figure 53 The front final drive 70 can be inserted through the opening 1350 of the diaphragm plate 1334. The front final drive 70 is inserted until the mounting insert 496 is aligned with the corresponding openings 1362 and 1364 of the left-hand side plate 1336. Figure 54 Anchors 1390 and 1392 are provided, which are L-shaped in construction and have vertical portions 1390a and 1392a, and horizontal portions 1390b ​​and 1392b. Orifices 1390c, 1392c, 1390d, and 1392d are provided for installation, as described herein. Anchors 1390 and 1392 are aligned with the mounting insert 496 of the front final drive 70, whereby the vertical portions 1390a and 1392a are connected through openings 1362 and 1364 to contact the mounting insert 496. This positions the horizontal portions 1390b ​​and 1392b on the bases 1374 and 1376, respectively. This also aligns the orifices 1390d and 1392d with orifices 1374a and 1376a, respectively. Vertical fasteners 1400 and 1402 can be received through orifices 1390d and 1392d, and orifices 1374a and 1376a, to receive counter fasteners 1404 and 1406. Simultaneously, fastener 1410 can be received through orifice 1390c, through the front mounting insert 496, and through orifice 1382 of the right-hand side plate 1338 to receive counter fastener 1414. Similarly, fastener 1412 can be received through orifice 1392c, through the rear mounting insert 496, and through orifice 1384 to receive counter fastener 1416.

[0191] In the preferred installation method, horizontal fasteners 1410 and 1412 are first inserted, while vertical fasteners 1400 and 1402 and anchors 1390 and 1392 are loosely installed. Horizontal fasteners 1410 and 1412 are twisted to their nominal torque ratings, which does not provide preload stress to anchors 1390 and 1392. Instead, anchors 1390 and 1392 remain resting on their respective surfaces 1374 and 1376. Once horizontal fasteners 1410 and 1412 have been twisted, fasteners 1400 and 1402 can subsequently be twisted to provide the final positioning of the front final drive 70.

[0192] Now for reference Figure 52 The removable bumper 1324 includes a plate 1430 to which a safety lever 1432 is attached. A fastener 1434 can pass through the plate 1430 to receive and enter a threaded fastener within a connector 1342. Therefore, it should be understood that in order to remove the front drive 70, the bumper 1324 is removed and the front drive 70 can be pulled through the opening 1350 of 1334.

[0193] refer to Figures 56 to 114 The article was made public regarding... Figures 1 to 55 Various alternative embodiments and / or additional features and systems of vehicle 2 of the disclosed embodiments, with the same or similar reference numerals for the same parts. Regarding Figures 56 to 68 Frame 20 and cab frame 28 ( Figures 1 to 9 Alternative embodiments of the ) are disclosed as frame 2020 and cab frame 2008. More particularly, as Figures 56 to 60 As shown, frame 2020 includes a generally longitudinally extending frame tube 2102 and a generally vertically extending frame tube 2114. Frame 2020 further includes frame members 4000 coupled to and generally inwardly extending from frame tube 2114. Illustratively, frame 2020 includes at least two frame members 4000, and each frame member 4000 includes a bracket 4002 coupled thereto. In various embodiments, the bracket 4002 is integratedly coupled to the frame member 4000 and may be integratedly formed with the frame member 4000 (e.g., by weld, adhesive, or rivet). The bracket 4002 includes a fastening member 4004, which illustratively defines a rod or other structure configured to support a load coupled thereto. In this way, the bracket 4002 and the fastening member 4004 define an integrated fastening assembly supported by the frame 2020, such that the load at the fastening member 4004 and the bracket 4002 is also supported by the frame 2020 and can be distributed through at least a portion of the frame 2020.

[0194] Still referencing Figures 56 to 60 The frame 2020 may include additional supports 4008 and fastening members 4010. For example, support 4009 may include a fastening member similar to fastening member 4004, or, as further disclosed herein, a fastening member similar to fastening member 4010. Additionally, the rear portion of the frame 2020 includes a generally longitudinally extending frame tube 2172, and generally vertically extending frame tubes 2240 and 4006 that are connected to and / or positioned adjacent to frame tube 2172. Illustratively, frame tube 4006 is positioned longitudinally rear of frame tube 2240 and directly connected to frame tube 2172. In one embodiment, the frame 2020 includes at least two frame tubes 4006, and each frame tube 4006 includes a support 4008 integratedly connected thereto. The bracket 4008 is also integratedly connected to the frame tube 2174, which is positioned above the frame tubes 2240 and 4006 and extends generally longitudinally. For example, at least... Figure 57 As shown, the upper part 4012 of the bracket 4008 is integratedly connected to the frame tube 2174, and the lower part 4014 of the bracket 4008 is integratedly connected to the frame tube 4006.

[0195] The bracket 4008 includes a fastening member 4010, illustratively defined as a rod or other structure configured to support a load coupled thereto. In one embodiment, the fastening member 4010 is coupled to the lower portion 4014 of the bracket 4008; however, the fastening member 4010 may be coupled to any portion of the bracket 4008. In this way, the bracket 4008 and the fastening member 4010 define an integrated fastening assembly supported by the frame 2020, such that the load at the fastening member 4010 and the bracket 4008 is also supported by the frame 2020 and can be distributed through at least a portion of the frame 2020.

[0196] It should be understood that brackets 4002, 4008 and fastening members 4004, 4010 can be positioned at any height along the frame 2020. Furthermore, brackets 4002, 4008 and fastening members 4004, 4010 can be positioned along the longitudinal centerline L of vehicle 2. Figure 5 Within a predetermined lateral distance of the centerline L. For example, the fastening members 4004, 4010 may be laterally positioned approximately 12-36 inches outside the centerline L, and more specifically, approximately 24 inches outside the centerline L. Furthermore, as shown, fastening members 4004, 4010 are included on both the left and right sides of vehicle 2, such that there is at least one fastening member 4004, 4010 on each lateral side of the centerline L. Additionally, the fastening members 4004, 4010 may include double-shear U-clamp attachments to load the corresponding frame tubes and distribute the load to these segments or tubes or frames 2020.

[0197] refer to Figure 61 and Figure 62 An alternative embodiment of the cab frame 2028 (with) is shown. Figures 1 to 9 and Figures 46 to 50 (As shown in comparison). Cab frame 2028 with seats 24, 26 ( Figure 1 The cab frame 2028 extends upwards and is connected to the frame 2020. The cab frame 2028 includes frame members or frame portions 3070, 3072, 3080, and 3082, each of which is connected to the frame 2020 via a complementary coupler. Figure 56In one embodiment, the cab frame 2028 is a single welded piece, such that frame members 3070, 3072, 3080, 3082 and any other frame members of the cab frame 2028 are integrally formed together (e.g., defining a single welded piece). Various frame members or frame portions of the cab frame 2028 may include openings or apertures 4016 configured to expose the internal volumes of these frame members or frame portions. Openings 4016 are illustratively shown on frame portions 3072 and 3082; however, openings 4016 may be positioned on frame members or frame portions 3070 and / or 3080. Openings 4016 are configured to allow various electrical wires, conduits, cables, or other components of the vehicle 2 to extend within the cab frame 2028 without being exposed, such that these components can extend between frame members 3072 and frame portions 3080, 3082 without being exposed to the seating area 22. Figure 1 This can protect such parts from damage or wear and also improve the aesthetics of vehicle 2.

[0198] refer to Figures 63 to 68 The rear of frame 2020 includes a universal bed support area 2200 (with at least) of alternative embodiments. Figure 8 and Figure 9 Compared to support region 200. Support region 2200 includes pipes 2206 and 2208, wherein pipe 2208 extends generally longitudinally and is connected to pipe 2206, and pipe 2206 extends generally laterally and perpendicular to pipe 2208. Support region 2200 further includes a strut 4017 extending between pipes 2208 and generally parallel to pipe 2206. Illustratively, strut 4017 is positioned longitudinally forward of pipe 2206.

[0199] In one embodiment, the tube 2208 is removably attached to a bracket 4020 on a cross member 4018 using fasteners 4022. The cross member 4018 may be part of the frame 2020 and attached to the frame tube 2240. At least as Figure 64 and Figure 65 As shown, the cross member 4018 is positioned vertically below the transverse tube 218. The tube 2208 extends longitudinally from the cross member 4018 and its rear end is connected to the tube 2206.

[0200] like Figure 56AAs best shown, bracket 4020 is coupled to cross member 4018, and more specifically, bracket 4020 extends through a recess or opening 4019 in cross member 4018. Illustratively, opening 4019 is a through opening, wherein a portion of bracket 4020 extends completely through opening 4019. In this way, the forward portion of bracket 4020 is positioned in front of cross member 4018 and the rearward portion of bracket 4020 is positioned behind cross member 4018. Bracket 4020 may be welded or otherwise permanently fixed to cross member 4018 at opening 2019, such that the welded or fixed joint completely surrounds opening 4019 and increases the size of the welded or fixed joint. Alternatively, the welded or fixed joint may be positioned at a portion of opening 4019 and may not completely surround opening 2019. This configuration of the bracket 4020 and the cross member 4018 allows the support area 2200 to support multiple components of the vehicle 2, such as the coolant bottle 3000, the universal bed 2088, and multiple portions of the intake assembly 2608 and the exhaust port 2986, as further disclosed herein, because the load from these components can be distributed through other portions of the frame 2020 (e.g., the cross member 4018) and does not need to be supported only at the bracket 4020 and the pipe 2208.

[0201] The tube 2206 is removably connected to the bracket 4008 using fastener 4024. For example... Figures 63 to 65 As best shown, the upper surfaces of tubes 2206 and 2208 and support column 4017 are flush with each other, so that tubes 2206 and 2208 and support column 4017 define generally planar or flat surfaces. In this way, support region 2200 is configured to support at least one component of vehicle 2 thereon, and more particularly, to support a general-purpose bed 2088 thereon.

[0202] refer to Figure 67 and Figure 68The bottom surface 4026 of the universal bed 2088 includes a guide 4028. The guide 4028 extends downward from the bottom surface 4026 and can be removably coupled to the bottom surface 4026 or formed integrally with the bottom surface 4026. The guide 4028 is configured to extend along the transverse inner surface 2209 of the tube 2208 such that the guide 4028 transversely overlaps a portion of the tube 2208. In this way, when the universal bed 2088 is positioned on the support region 2200, the guide 4028 is positioned and contacts the inner surface 2209 of the tube 2208, so that the universal bed 2088 is correctly positioned to be centered on and secured to the support region 2200. It should be understood that the guides 4028 are configured to be spaced apart from each other if necessary to receive or otherwise accommodate components of the support region 2200, such as the support column 4017. When correctly positioned on the support area 2200, the general-purpose bed 2088 can be fastened to the support area 2200 using connectors (such as bolts, screws, straps, etc.).

[0203] Still referencing Figures 63 to 68 The support area 2200 not only supports the general-purpose bed 2088 but is also configured to support other components of the vehicle 2. For example, such as... Figure 63 and Figure 66 As best shown, the support region 2200 is configured to support a portion of the intake assembly 2608, a portion of the exhaust assembly 2986, a portion of the vehicle 2's cooling assembly (e.g., coolant bottle 3000), and various body panels of the exterior body 80 (e.g., rear fenders, rear closure panels, rear bumpers). Illustratively, the forward portion of the support region 2200 supports and can be connected to the air box 4030 of the intake assembly 2608, such that the air box 4030 is supported on at least the intake manifold 2208. Additionally, the rearward portion of the support region 2200 supports and can be connected to the muffler or silencer 4032 of the exhaust assembly 2986. Figure 66 As shown, bracket 4034 extends from at least tube 2208 and is coupled to support arm 4036, which is attached to muffler 4032.

[0204] refer to Figure 69 and Figure 70 The front suspension 2040 is shown. (See the section on...) Figure 12 and Figure 13The front suspension 2040 includes an upper alignment arm or A-arm 2280, a lower alignment arm or A-arm 2282, and an LFE or shock absorber 2284. The LFE 2284 is operatively coupled to the lower A-arm 2282 via a U-clamp 2298. More specifically, the U-clamp 2298 has a generally U-shaped body extending between an upper end 4040 and a lower end 4042. The lower end 4042 is removably coupled to the lower A-arm 2282 by a fastener 4044 (such as a bolt). The U-clamp 2298 is configured to receive or bridging a portion of the half-shaft 2290 such that the U-clamp 2298 and the LFE 2284 do not interfere with the desired position or rotational movement of the half-shaft 2290. In this way, the half-shaft 2290 is vertically positioned between the upper end 4040 and the lower end 4042 of the U-clamp 2298.

[0205] like Figure 70 As best shown, the upper end 40 of the U-shaped clip 2298 is coupled to the lower portion of the LFE 2284. More specifically, the upper end 4040 of the U-shaped clip 2298 includes an aperture 4049 configured to receive a threaded end 4048 of the LFE 2284. The threaded end 4048 aligns with the piston assembly 4046 of the LFE 2284 and, illustratively, can be collinear with the rod portion of the piston assembly 4046. Additionally, the lower portion of the LFE 2284 includes a spring retainer 4047, which is rotatably oriented or locked to the U-shaped clip 2298 via an interface. Illustratively, the U-shaped clip 2298 includes a latch 2299 that engages within a slot 4045 on the spring retainer 4047 to allow the rod 4046 to pass through when the spring retainer 4047 is mounted on the LFE 2284.

[0206] By using the U-shaped clip 2298, the front suspension 2040 and the steering components of the vehicle 2 can be compactly packaged, and a longer LFE 2284 can be used without compromising the weight of the vehicle 2.

[0207] refer to Figures 69 to 73 The front braking system 2420 is shown positioned adjacent to the front wheel hub 2292. As shown, the braking system 2420 is coupled to the steering spindle 2390 and includes a brake caliper 2422, a disc 24, and a brake disc 2426. The hub 2292 includes a plurality of orifices 2430, 2440 that receive fasteners (not shown) passing through them, and the disc 2426 includes an orifice 2436 such that the hub 2292 and the disc 2426 can be coupled together and coupled to a portion of the spindle 2390. The caliper 2422 may include a castellated piston, which reduces weight, as further disclosed herein, and can facilitate thermal management of the front braking system 2420.

[0208] The caliper 2422 and disc 2424 are connected to the brake bracket at 2442. Figure 72 This allows the disc 2424 to be held on opposite sides of the brake disc 2426. Alternatively, the brake disc 2426 may be shown as a single component, including the disc 426, at least a portion of the hub 2292, and fasteners (not shown).

[0209] The construction of the front braking system 2420 allows for the integration of the caliper 2422 with the spindle 2390, thereby reducing the weight and size at the ground engagement member 4 and minimizing the need for additional protection measures for the brake caliper 2422. More specifically, the braking system 2420 and the steering arm 400 ( Figures 12 to 15 ) and main shaft 2390 are connected at ball joint 4041 ( Figure 71 The connection at point R is positioned on the wheel rotation axis. Figure 69 The brake caliper 2422 may require less protection against debris and mud buildup than in other locations, and the weight and size of the ground engagement member 4 and / or the front braking system 2420 may be reduced.

[0210] refer to Figure 74 The rear braking system 4050 is shown and may be similar to the front braking system 2420. The rear braking system 4050 includes a brake caliper 4052, a disc (not shown), and a brake disc 4054. The caliper 4052 and the disc can be coupled to a brake bracket at 4054 such that the disc is held on opposite sides of the brake disc 4054.

[0211] Now for reference Figures 74 to 78 The image shows a rear suspension 2042. The rear suspension 2042 includes a trailing arm 2500, an upper radius arm or rod 2506, a lower radius arm or rod 4062, an LFE or shock absorber 4060, and a toe link or arm 4064. (The image is missing from the original text.) Figure 74 As best shown, the LFE 4060 is attached to the upper surface of the trailing arm 2500 via a shock mount 4066. The shock mount 4066 is longitudinally positioned along the length of the trailing arm 2500 and is positioned at the rear end of the trailing arm 2500 or longitudinally in front of the steering knuckle carrier 4058. The steering knuckle carrier 4058 may be stamped to reduce the weight of the rear suspension 2042. The steering knuckle carrier 4058 may be cast to reduce the complexity of the rear suspension 2042. The upper surface of the trailing arm 2500 may also include a bracket 4067 configured to receive part of the torsion bar assembly 510. Figure 21 ).

[0212] The steering knuckle carrier 4058 of the trailing arm 2500 includes an opening 4068 configured to receive a rear half-shaft 2078. The steering knuckle carrier 4058 further includes a rearward surface 4070 configured to support the outer ends of an upper radius rod 2506 and a lower radius rod 4062. More specifically, the rearward surface 4070 includes a mounting member 4072 configured to support the radius rods 2506 and 4062. In one embodiment, the mounting member 4072 is integrally formed with the steering knuckle carrier 4058 of the trailing arm 2500, while in other embodiments, the mounting member 4072 is removably coupled to the steering knuckle carrier 4058. The outer ends of the radius rods 2506 and 4062 are longitudinally positioned between the mounting member 4072 and the steering knuckle carrier 4058, such that the mounting member 4072 defines the rearmost surface of the rear suspension 2042. Illustratively, the radius rods 2506 and 4062 are positioned longitudinally behind the rear half-shaft 2078.

[0213] Still referencing Figures 74 to 78 The trailing arm 2500 includes an opening 4074 that extends between an inner portion 4076 and an outer portion 4078. The inner portion 4076 and the outer portion 4078 may define a flap design and are stamped parts, which together define the trailing arm 2500. The portions 4076 and 4078 may be symmetrical on the right and left sides of the rear suspension 2042, which minimizes tooling during manufacturing and thus reduces costs. Additionally, because the portions 4076 and 4078 are stamped, the rear suspension 2042 can be made lighter.

[0214] The trailing arm 2500 extends between a forward portion 4090 and a steering knuckle carrier 4058. The forward portion 4090 includes a connector 4092 configured to be operably coupled to the frame 2020 and allow generally vertical movement of the trailing arm 2500 during vehicle 2 operation. The steering knuckle carrier 4058 is coupled to a rearward portion 4091 of the trailing arm 2500, illustratively defining a "V" shape at 4093. The rearward portion 4091 can be fixed to the steering knuckle carrier 4058 by welding. The construction of the trailing arm 2500 and its connection to the steering knuckle carrier 4058 allow for more efficient load distribution at the trailing arm 3500 and increase the amount of welding at the interface between the rearward portion 4091 and the steering knuckle carrier 4058.

[0215] Opening 4074 extends fully through trailing arm 2500 and is configured to receive a portion of toe link 4064. More specifically, toe link 4064 extends generally longitudinally between a front end 4080 and a rear end 4082. The front end 4080 includes a connector 4084 configured to operably engage with a portion of frame 2020. The rear end 4082 includes a hub assembly 4088 configured to operably engage with rear ground engagement member 6. Figure 1 The connector 4086 can define a joint subjected to double shear loading. The corresponding bearing can be radially loaded, thus minimizing the risk of the connector 4086 and the bearing pulling apart as the connector 4086 wears.

[0216] The connector 4086 can be positioned within the opening 4087 of the steering knuckle carrier 4058 of the trailing arm 2500. For example... Figures 76A to 76C As best shown, the connector 4086 may include a bolt 4400, an eccentric washer 4402, and a nut 4404, which together provide the ability to adjust the alignment of the toe link 4064 by rotating the bolt 4400 before tightening the nut 4404. The bolt 4400 may be mechanically connected to the washer 4402 by knurling, D-profile, or other shapes. The washer profile is eccentric to the bolt axis, and the steering knuckle carrier 4058 may have a locating latch that the washer 4402 contacts. In this way, as the bolt 4400 is rotated, the washer 4402 moves the bolt axis back and forth in the opening. Once the bolt 4400 has been rotated to provide the desired alignment of the toe link 4064, the bolt head is secured in place and the nut 4404 is tightened to the desired torque.

[0217] like Figure 75 As best shown, the toe link 4064 extends diagonally through the opening 4074, such that the front end 4080 is positioned inside the outer side 4078 of the trailing arm 2500, while the rear end 4082 is positioned outside the inner side 4076 of the trailing arm 2500. In this way, the rear suspension 2042 can be constructed compactly so as not to interfere with other components or systems of the vehicle 2, such as the powertrain or drivetrain, but the opening 4074 provides sufficient space for the toe link 4064 to move with or relative to the trailing arm 2500 as needed.

[0218] Further details of the rear suspension 2042 may be disclosed in U.S. Patent Application No. 16 / 266,797, filed December 20, 2018, entitled “REAR SUSPENSION ASSEMBLY FOR A VEHICLE” (Attorney’s No. PLR-15-28340.05P-US), the disclosure of which is incorporated herein by reference in its entirety.

[0219] refer to Figures 79 to 93 The document discloses several components of the powertrain of vehicle 2. As disclosed herein, the powertrain of vehicle 2 includes at least engine 50 and CVT 52. Figure 23 and Figure 24 An arc-shaped spring assembly 4100 may be present at the interface between engine 50 and CVT 52 (also in...). Figure 41 (As shown in the diagram). More specifically, the arc spring assembly 4100 can be positioned between the crankcase of engine 50 and the transmission clutch 978 of CVT 52. Figures 39 to 41 In one embodiment, the arc spring assembly 4100 is directly coupled to the crankshaft 4102 of the engine 50 and the transmission clutch 978 of the CVT 52. Illustratively, as... Figure 81 As best shown, the arc spring assembly 4100 is directly coupled to the input end 4104 of the crankshaft 4102. By positioning the arc spring assembly 4100 at the input end 4104 of the crankshaft 4102 and at the adjacent transmission clutch 978 of the CVT 52, vibrations at the engine 50 are absorbed and not transmitted to the CVT 52. In other words, the arc spring assembly 4100 reduces or dampens the rocking force applied from the crankshaft 4102 during engine ignition events, thereby increasing the life of the CVT 52 by reducing torsional pulsation and thus lowering the temperature of the CVT belt.

[0220] The arc spring assembly 4100 includes an arc spring damper assembly 4110, a gear ring 4112 positioned around a flexible plate 4111, and a hub 4114. The hub 4114 is coupled to the input end 4104 of a crankshaft 4102. The hub 4114 includes orifices 4120, at least some of which are aligned with orifices 4122 on the input end 4104 to receive fasteners 4118 (e.g., bolts, rivets, etc.). The flexible plate 4111 and the ring gear 4112 are positioned adjacent to the hub 4114 such that the hub 4114 is positioned between the flexible plate 4111 and the input end 4104 of the crankshaft 4102. The gear ring 4112 has a larger diameter than the hub 4114 and includes a plurality of teeth 4124 along its outer circumference. The flexible plate 4111 includes a plurality of positioning members (e.g., pins or studs) 4113 configured to properly position the CVT 52 relative to the engine 50 (e.g., for proper positioning on the flywheel of the engine 50). Additionally, the flexible plate 4111 includes a plurality of mounting members 4115 (e.g., studs) configured to engage with the arcuate spring damper assembly 4110. The flexible plate 4111 also includes a plurality of orifices 4126 configured to align with orifices 4120 and 4122 to receive fasteners 4118 for engaging the flexible plate 4111 and hub 4114 to the input end 4104 of the crankshaft 4102.

[0221] Mounting plate 4116 can be positioned on the opposite side of flexible plate 4111 relative to hub 4114, such that flexible plate 4111 is positioned between mounting plate 4116 and hub 4114. Mounting plate 4116 includes a plurality of orifices 4128 configured to align with orifices 4120, 4122, 4126 to receive fasteners 4118 for connecting mounting plate 4116 to flexible plate 4111, hub 4114 and input terminal 4104.

[0222] The arc-shaped spring damper assembly 4110 is positioned adjacent to the mounting plate 4116 such that the mounting plate 4116 is located between the flexible plate 4111 and the arc-shaped spring damper assembly 4110. The arc-shaped spring damper assembly 4110 includes a spring body cover 4130, a transmission plate 4132, and a threaded orifice 4134. The threaded orifice 4134 is configured to receive a portion of the shaft 824 and / or shaft 828. Figure 41 This causes the crankshaft 4102 to drive the transmission clutch 978 of the CVT 52 via the arc-shaped spring assembly 4100. Figure 41The threaded orifice 4134 can be centrally positioned on the spring body cover 4130. In this way, the arcuate spring assembly 4100 is directly connected to the crankshaft 4102 and the drive clutch 978. Through this direct connection between the crankshaft 4102 and the drive clutch 978, the arcuate spring assembly 4100 becomes a decoupling device between the drive clutch 978 and the engine 50. The use of the arcuate spring assembly 4100 reduces the lateral load on the crankshaft 4102, thereby improving the life of the engine 50 and the belt life of the CVT 52, as further disclosed herein.

[0223] The transmission plate 4132 includes a connector 4136, which is configured to receive a mounting member 4115 on the flexible plate 4111 to connect the arc spring damper assembly 4110 and the flexible plate 4111 together.

[0224] like Figure 83 and Figure 84 As best shown herein, the spring body cover 4130 includes at least one spring 4138 extending at least partially around a threaded orifice 4134 and having a coiled shape. The spring 4138 can be secured by a spring retainer 4139. The spring 4138 is configured to receive and dampen vibrational forces from the engine 50, thereby minimizing the transmission of such vibrational forces to the CVT 52, as further disclosed herein. In this way, the arcuate spring assembly 4100 is configured to increase the lifespan of the CVT 52 by minimizing wear on the CVT 52.

[0225] More specifically, the torque path through the arc-shaped spring damper assembly 4110 is... Figure 84 The torque is shown as an arrow. The torque is initially transmitted via the drive plate 4132, then via the spring body cover 4130. The torque is transmitted via the spring body cover 4130, then along the fastener 4118 between the spring body cover 4130 and the spring retainer 4139. The torque is then transmitted via the spring retainer 4139 before being transmitted via the spring 4138, and finally via the flange 4131 and hub 4137, which generally surround the threaded opening 4134. The spring 4138 provides a damper capacity stop when the inner diameter coil becomes seamless. It should be understood that if the torque increases by an amount greater than the spring capacity, the torque still follows... Figure 84 The same torque path disclosed in the document.

[0226] refer to Figures 85 to 86B Further details of the powertrain of vehicle 2 have been disclosed. Illustratively, and similarly... Figure 53As disclosed regarding supporting the front drive 70 on frame 20 or 2020, the lower longitudinal tube 1330 includes a threaded insert 1340, and the upper longitudinal tube 1332 includes a threaded insert 1342. A front base plate 1334 is coupled to the lower longitudinal tube 1340 and the upper longitudinal tube 1342, and includes an opening 1350 that generally mates to allow passage of the front drive 70 therethrough, as described in more detail herein. A side plate 1336 is generally coupled to the left-hand side lower longitudinal tube 1330 and upper longitudinal tube 1332. The left plate 1336 includes an opening at 1360 to allow access between the front drive 70 and the left front wheel. The left side plate 1336 further includes a front opening at 1362 and a rear opening at 1364, the front opening at 1362 and the rear opening at 1364 aligning with a mounting insert 496, as described further herein. The front base 1370 is positioned below the orifice 1362, and the rear base 1372 is positioned below the opening 1364. The base 1370 defines a mounting surface at 1374, while the base 1372 defines a mounting surface at 1376.

[0227] Fasteners 1410 and 1412 are installed via plate 1336 and via front drive 70 and are tightened at the joint without any preload loss. Plate 1336 is a casting with a smooth radius and provides full contact. More specifically, bosses on plate 1336 have proper contact with the isolator to prevent tearing and cutting of the isolator. Once fasteners 1410 and 1412, which are horizontal fasteners, are tightened, vertical fasteners 1400 and 1402 are tightened. If the order of tightening the horizontal and vertical fasteners is reversed, plate 1336 will be prestressed when bending and may fatigue prematurely. In this way, front drive 70 utilizes a sliding joint to release bolt preload, facilitating installation.

[0228] refer to Figure 87A and Figure 87B And similarly to the front drive 70, the rear drive 2076 can be similarly mounted to the frame 2020. More specifically, the rear drive 2076 may include a boss 4410, which extends generally laterally and is configured to receive a removable fastener 4412 passing through it. The fastener 4412 also extends through an opening in a mounting bracket 4414, thus connecting the mounting bracket 4414 and the housing of the rear drive 2076 together with a connector 4416. It should be understood that the bracket 4414 can be removed from the frame 2020 to facilitate maintenance and assembly of the rear drive 2076.

[0229] Bracket 4414 connects to post 4420, which extends between and connects to frame tubes 2174. More specifically, fastener 4422 extends generally vertically between corresponding openings in post 440 and bracket 4414 to connect bracket 4414 and post 4420 together. Fastener 4422 extends through isolator 4421 on bracket 4414. Connector 4424 is configured to receive part of fastener 4422 to secure bracket 4414 to post 4420. Because rear drive 2076 is connected to bracket 4414, rear drive 2076 is also connected to post 4420 via bracket 4414.

[0230] The housing of the rear drive 2076 further includes a second boss 4418 configured to receive a fastener 4426 for coupling the forward portion of the rear drive 2076 to the upright bracket 4428. Illustratively, the fastener 4426 extends through an aperture in the upright bracket 4428 and through the boss 4418 of the rear drive 2076 for coupling with the connector 4430. The upright bracket 4428 extends upward from the frame tube 2172.

[0231] Still referencing Figure 87A and Figure 87B The rear drive 2076 can be installed in a double-shear manner and also in a way that avoids clamp load loss after following the installation sequence. To avoid clamp load loss, the following installation sequence can be used. First, the rear drive 2076 is assembled with the frame 2020 by lowering the rear drive 2076 into the rear sleeve between the uprights 4428. Although the uprights 4428 can be welded to the frame tube 2172, the uprights 2172 create a bracket that holds the rear drive 2076 in place, and the fasteners 4426 are then assembled via the boss 4418. Next, the bracket 4414 is installed into the sleeve of the support 4420 in the front-rear direction, followed by the fasteners 4422. Then, the vertical fasteners 4422, which can be double-shear bolts, are loosely added. Tighten the fasteners 4426 first, then tighten the fasteners 441. Finally, tighten the fasteners 4422. Therefore, fastener 4412 has no preload loss in the joint and this construction allows for some flexibility and tolerance to be superimposed.

[0232] refer to Figures 88 to 93The powertrain of vehicle 2 includes a vent pipe or duct 4140. The vent pipe 4140 is configured to prevent engine oil from entering the combustion system of engine 50 if vehicle 2 is in a rollover or overturned condition. For example, at an angle of approximately 80° relative to vertical, oil in the oil sump of engine 50 may move through the vent pipe 4140 and may enter the intake manifold of engine 50, potentially causing damage to the cylinders and other components of engine 50. Therefore, it is necessary for the vent pipe 4140 to mechanically close this flow path to the intake manifold during a rollover.

[0233] The vent pipe 4140 includes a first portion or engine portion 4142 and a second portion or intake portion 4144, the first portion or engine portion 4142 being configured to connect to the main oil sump 648 of the engine 50. Figure 25 The second part or intake portion 4144 is configured to connect to the intake manifold of the engine 50. More specifically, the first part 4142 includes a connector or connector 4146 configured as a quick-connect coupling for attachment to the oil sump 648 or other parts of the engine 50, and the second part 4144 includes a connector or connector 4148 configured as a quick-connect coupling for attachment to the intake manifold.

[0234] Additionally, the vent 4140 includes a check valve 4150 positioned at an interface 4152 of the first portion 4142 and the second portion 4144. The check valve 4150 includes a housing 4154 having a first end 4156 and a second end 4158, and a check ball 4153. The first end 4156 is generally positioned in the first portion 4142 of the vent 4140, while the second end 4158 is generally positioned in the second portion 4144 of the vent 4140. The housing 4154 may be a single component configured to receive the check ball 4153, such that the first end 4156 and the second end 4158 can be integrally formed together. In various embodiments, the housing 4154 may be constructed from aluminum tubing or injection-molded plastic ultrasonically welded together. The materials constituting the housing 4154 and the check ball 4153 are configured to withstand high engine oil temperatures (e.g., approximately 150°C) and to completely seal hot oil from entering the intake manifold of the engine 50.

[0235] The first end 4156 includes at least one stop member 4160, which is configured as a recessed or reduced-diameter portion of the housing 4154, preventing the check ball 4153 from moving beyond this portion of the first end 4156. The second end 4158 includes a base 4162, which is configured to receive the check ball 4153 when it is within the second end 4158. The base 4162, which may be made of a rubber material, includes a cavity 4164 extending through the base 4162 and is configured to receive fluid depending on the operation and position of the vehicle 2. In one embodiment, the flow area through the housing 4154 may be approximately seven times larger than the flow area through the cavity 4164. Both the first end 4156 and the second end 4158 include a guide 4166, which is configured to ensure that the check ball 4153 remains centered within the housing 4154 for a complete seal if necessary.

[0236] During operation, and refer to Figure 92 and Figure 93 If vehicle 2 overturns or rolls over, the check ball 4153 moves toward seat 4162 to prevent oil from flowing from oil sump 648 into the intake manifold of engine 50. Figure 92 However, when vehicle 2 is upright and operating along the ground surface, check ball 4153 can move away from seat 4162 to allow gas pressure or other fluids from engine 50's crankcase to be exhausted during powertrain operation. Figure 93 ).

[0237] refer to Figures 94 to 96 The powertrain of vehicle 2 includes intake systems 608 and 2608, as disclosed herein. Intake systems 608 and 2608 include intake ports 4170 positioned substantially adjacent to the general-purpose bed 2088. Illustratively, intake ports 4170 are located on the right and left sides of vehicle 2, and one intake port 4170 is configured to supply air to engine 50, while the other intake port 4170 is configured to supply air to CVT 52. Intake air from intake port 4170 to engine 50 is provided for combustion, while intake air from the other intake port 4170 to CVT 52 provides cooling air for cooling clutches 978 and 980 and belts.

[0238] Each of the air intake ports 4170 includes a filter or other cover 4172 coupled to a baffle 4174. The baffle 4174 may be defined as part of the external body 80, 2080 and may receive the filter 4172 (e.g., removably coupled to the filter 4172), or may be formed integrated with the filter 4172. The ports 4170 extend outward from the vehicle 2, such that the ports 4170 face the ambient air surrounding the vehicle 2 and are configured to draw ambient air into them.

[0239] To minimize noise caused by the incoming airflow into port 4170, a baffle cover or barrier 4176 may be positioned along a portion of baffle 4174. More specifically, because port 4170 is positioned at approximately the same vertical height as a portion of the seat back in seating area 22, noise at port 4170 may be audible to the operator and / or passenger; however, the baffle cover 4176 deflects the sound backward and away from seating area 22.

[0240] Illustratively, the baffle cover 4176 includes an inwardly facing wall 4176a, an upper surface 4176b, and a rearward extension 4176c. In this way, the baffle cover 4176 generally surrounds the upper and inner surfaces of the baffle 4174, while fully exposing the outer surfaces of the baffle 4174 and the filter 4172 to receive ambient air. The baffle cover 4176 can be removably attached to the baffle 4174 by means of fasteners 4178 extending through at least the upper surface 4176b. In this way, the baffle cover 4176 can be removed for cleaning and removal of any dirt or grime buildup. It should be understood that the baffle cover 4176 does not extend into the universal bed 2088 and therefore does not impede the usable cargo volume or space of the universal bed 2088.

[0241] refer to Figures 97 to 99 The powertrain of vehicle 2 includes exhaust ports 986 and 2986, as disclosed herein. Exhaust ports 986 and 2986 include a muffler 4032, which is supported at the rear end of vehicle 2 and, more particularly, by a support region 2200. Exhaust ports 986 and 2986 further include an exhaust outlet or tailpipe 4180 consisting of a duct portion 4182 and an outlet portion 4184. The duct portion 4182 may be removably coupled to or integrated with a portion of the muffler 4032, and the outlet portion 4184 is fluidly coupled to the muffler 4032 via the duct portion 4182.

[0242] Illustratively, the outlet portion 4184 is removably connected to the conduit portion 4182 at the intersection or connection position 4188, and is secured to the conduit portion 4182 with at least a removable fastener 4186. Figure 98 A collar or other connecting or retaining member may also be used to connect the outlet 4184 to the conduit 4182 at the intersection 4188.

[0243] The outlet portion 4184 may include multiple intersecting sides. Illustratively, the shape of the outlet portion 4184 is defined by four sides and generally defines a trapezoid. For example... Figure 97 and Figure 98As best shown, the length of the upper side 4184a can be greater than the length of the lower side 4184b. The left side 4184c and the right side 4184d can extend between and connect with the upper side 4184a and the lower side 4184b, such that the left side 4184c and the right side 4184d extend diagonally inward toward the center line L, thereby connecting with the lower side 4184b.

[0244] The outlet 4184 is defined as a double-walled outlet, comprising a first wall segment 4190 and a second wall segment 4192, the first wall segment 4190 extending from and substantially collinear with the conduit portion 4182, and the second wall segment 4192 surrounding a portion of the first wall segment 4190. In one embodiment, the first wall segment 4190 and the second wall segment 4192 are integrally formed with each other, thus increasing the return edge of the outlet 4184. In this way, the first wall segment 4190 and the second wall segment 4192 radially overlap each other to define the double-walled structure. In various embodiments, any portion of the exhaust ports 986, 2986 may include an insulating cover or wrapping to shield adjacent components of the vehicle 2 from heat generated within the exhaust ports 986, 2986, and / or to strategically manage heat within the exhaust ports 986, 2986 at various points along the system.

[0245] In one embodiment, the exhaust port 2986 is a central exhaust port, such that the outlet portion 4184 is positioned along the centerline L. Figure 5 However, various body panels of the outer body 80 may also be located at this position, therefore, it is necessary to ensure that the temperature of the exhaust port 2986 at the location of the body panels of the outer body 80 does not exceed a threshold that is detrimental to the body panels. By configuring the outlet 4184 as a double-walled outlet, the cumulative thermal conductivity of the outlet 4184 is reduced, thereby protecting the body panels adjacent to the outlet 4184.

[0246] refer to Figure 100 The powertrain of vehicle 2 may be equipped with a cooling system to provide cooling to various components of the powertrain, such as engine 50. The cooling system includes a coolant reservoir 3000, which may be similar to... Figure 42 Coolant bottle 1000. Coolant bottle 3000 can be supported on support area 2200, such as... Figure 66 As shown, and illustratively, it can be supported on the pipe 2208 at a location generally adjacent to the air box 4030. The coolant bottle 3000 includes a housing 3002 configured to store coolant fluid, and more particularly, includes an upper housing portion 3002a and a lower housing portion 3002b. The lower housing portion 3002b includes a notch or recess 3003 positioned adjacent to the lower or bottom surface 3004 of the housing 3002.

[0247] The recess 3003 is configured to receive a sensor 3006. The sensor 3006 is configured to detect the coolant level within the coolant reservoir 3000. Based on the positions of the recess 3003 and the sensor 3006 (i.e., adjacent to the lower surface 3004), the sensor 3006 can detect when the coolant level in the housing 3002 is low. The sensor 3006 is operatively coupled to the control system of the vehicle 2 via electrical or otherwise means, so that if the controller receives an input from the sensor 3006 indicating a low coolant level in the coolant reservoir 3000, the control system provides a visual or auditory warning to the operator. If necessary, the control system can control vehicle operation and / or powertrain parameters based on the coolant level in the coolant reservoir 3000 and the output of the sensor 3006.

[0248] refer to Figure 101 The vehicle's powertrain includes similar components. Figure 44 and Figure 45 The fuel tank 1050 disclosed herein includes a fuel tank 3050. The fuel tank 3050 may include a vent duct 4194, which is positioned along a portion of the frame 2020 and points toward the rear of the vehicle 2. More specifically, the vent duct 4194 extends upward toward the frame member 2182 and along the frame tube 2174 to enter the frame tube 2174 at an opening 4196 (also in...). Figure 56 and Figures 63 to 65 (As shown in the image). Frame tube 2174 is a hollow frame tube, and also includes an opening 4198 at its rear end (…). Figure 57 and Figures 63 to 65 A vent duct 4194 may extend through opening 4196 and along the length of frame pipe 2174 toward opening 4198. In this way, fuel (e.g., vapor) vented from fuel tank 3050 flows through vent 4194 and into frame pipe 2174 at opening 4196. The fuel vented from duct 4194 into frame pipe 2174 then flows rearward, through at least a length of vent duct 4194 and / or frame pipe 2174, and exits frame pipe 2174 and vehicle 2 at opening 4198. Therefore, even when vehicle 2 is lateral or tilted on a hill, for example, tilted to the left, the vented fuel is directed at the right side of vehicle 2 at frame pipe 2174 and is directed away from heat-generating components (e.g., powertrain components). In other words, the construction of the frame pipe 2174, openings 4196, 4198 and vent duct 4194 ensures that when the vehicle 2 is in a certain orientation, the fuel does deviate from the path within the frame pipe 2174 and flows to the hot zone of the frame 2020.

[0249] refer to Figure 102 and Figure 103In operation, the powertrain of vehicle 2 can be configured for pull-pull shifting. The powertrain of vehicle 2 further includes a shiftable transmission 2056, which can be similar to... Figure 3 The shiftable transmission 2056 is operable by a shift assembly 2060, which can be similar to... Figure 5 The shift assembly 60. Illustratively, the shift assembly 2060 is operatively connected to a first cable 4200 and a second cable 4202, both of which extend between the shift assembly 2060 and the shiftable transmission 2056.

[0250] Cables 4200 and 4202 are operatively connected to pulleys 4204 of a shiftable transmission 2056. At least a portion of cables 4200 and 4202 is supported on a bracket 4206 extending from a housing 4208 of the shiftable transmission 2056. The bracket 4206 is removably connected to the housing 4208 by fasteners 4209. Each cable 4200 and 4202 is connected to pulley 4204 at a connection point, and as... Figure 103 As best shown, cable 4200 is connected to pulley 4204 at connection position 4210, and cable 4202 is connected to pulley 4204 at connection position 4212. Connection positions 4210 and 4212 are fixed points on pulley 4204, such that movement of cables 4200 and 4202 pulls pulley 4204 at the corresponding connection positions 4210 and 4212, causing a gear change in the shiftable transmission 2056. Pulley 4204 keeps the effective radius of cables 4200 and 4202 constant, and therefore, the shifting force also remains constant. By using pulley 4204 and the two cables 4200 and 4202, the force required for shifting remains constant.

[0251] Cables 4200 and 4202 are configured as cables, such that, compared to known designs of transmissions that require a combination of pulling and pushing movement on a transmission bell crank to shift gears, movement in cables 4200 and 4202 is based on the movement of pulley 4204 of the shift assembly 2060. By configuring cables 4200 and 4202 as cables, the bell crank of a conventional shiftable transmission can be eliminated.

[0252] In one embodiment, cables 4200 and 4202 are of different sizes to ensure proper installation on vehicle 2. More specifically, connection positions 4210 and 4212 of pulley 4204 are defined as openings of different diameters to correspond to the different diameters of cables 4200 and 4202, such that only cable 4200 can be engaged with pulley 4204 at connection position 4210, and cable 4202 can be engaged with pulley 4204 at connection position 4212. Similarly, shift assembly 2060 also includes openings of different sizes corresponding to each of cables 4200 and 4202. Furthermore, bracket 4206 may also include openings of different diameters, such that bracket 4206 receives cable 4200 through a first opening for engagement with connection position 4210, and bracket 4206 receives cable 4202 through a second opening (having a different diameter than the first opening) for engagement with connection position 4212.

[0253] In operation, when the shift assembly 2060 is moved by the operator to a specific position to indicate the desired gear, cable 4200 or cable 4202 moves in response to the movement of the shift assembly 2060. The movement of cable 4200 or cable 4202 pulls pulley 4204. The movement of pulley 4204 causes a gear change in the shiftable transmission 2056. It should be understood that because cables 4200, 4202 are not connected to each other (e.g., because each cable 4200, 4202 has a separate connection position 4210, 4212 on pulley 4204), there is no corresponding and opposite movement of the other cable when one cable moves. Instead, both cables 4200, 4202 are configured to perform a pulling motion on pulley 4204 based on the movement of the shift assembly 2060.

[0254] refer to Figure 104 and Figure 105 To minimize noise and vibration from the powertrain and / or other components or systems of the vehicle 2 within the seating area 22, the vehicle 2 may include a panel 4220. Panel 4220 may be configured as a two-part panel comprising a first part 4222 and a second part 4224. The first part 4222 and the second part 4224 may be joined together in various ways, such as by adhesive or mechanical fasteners. The first part 4222 and the second part 4224 are connected to the vehicle 2 by fasteners 4226 and 4228. Fasteners 4226 and 4228 may be pins, bolts, screws, or other removable connecting or positioning components.

[0255] Illustratively, the first portion 4222 is positioned in front of the second portion 4224 such that the first portion 4222 is exposed to the seating area 22 while the second portion 4224 is not exposed. A fastener 4226 extends through an opening 4230 in the first portion 4222, and a fastener 4228 extends through an opening 4232 in the first portion 4222 for connection to the frame 2020 or other portions of the vehicle 2 within or defining the seating area 22.

[0256] The first part 4222 includes a curved or arcuate wall 4234 and a linear or flat wall 4236. Similarly, the second part 4224 includes a curved or arcuate wall 4238 and a linear or flat wall 4239. Walls 4234 and 4238 have complementary shapes, and therefore, wall 4234 is generally received within wall 4238. Walls 4236 and 4239 also have complementary shapes and can contact each other.

[0257] The first part 4222 can be made of polypropylene and fiberglass materials, such as Azdel material available from Federal Foam Technologies. The second part 4224 can be made of sound-absorbing foam material. In this way, the first part 4222 and the second part 4224 absorb sound and vibration from other parts of the vehicle 2 to minimize noise and vibration within the seating area 22. The materials of the first part 4222 and the second part 4224 can also be used to reduce the weight of the vehicle 2 compared to other sound-absorbing or vibration-damping materials. In addition, because at least the first part 4222 is exposed within the seating area 22 and therefore exposed to water, mud, dirt, and debris that may enter the seating area 22, the panel 4220 can be constructed as a waterproof panel.

[0258] refer to Figures 106 to 111 And as this article states regarding the external body 80 ( Figure 1 Further disclosed, the exterior body 2080 of vehicle 2 may include various features. The hood 2082 of the exterior body 2080 may include hinge assemblies 4240 for attaching grilles 4242 to various surfaces of the hood 2082. The grilles 42 may be used to receive and direct ambient air into at least one duct (e.g., the intake duct of a CVT 52) for a powertrain component. The grilles 4242 are positioned within openings 4243 in the hood 2082, and illustratively, the hood 2082 includes openings 4243 on both its left and right sides to support the two grilles 4242. The grilles 4242 and corresponding air intake ports at the grilles 4242 extend laterally outward from the centerline L. Figure 5 ), to receive ambient air for powertrain components (e.g., CVT 52).

[0259] The hinge assembly 4240 includes a shroud 4246 that generally extends around the periphery of the grille 4242. The shroud 4246 is attached to the hood 2082 by fasteners 4248 and 4250. More specifically, the fastener 4248 extends through an opening 4252 within the shroud 4246 and receives the fastener 4250 for attaching the shroud 4246 (enclosing the grille 4242) to the hood 2082.

[0260] The hinge assembly 4240 further includes a deflector plate 4254 connected to the grille 4242 via an upper plate 4256. The upper plate 4256 extends generally inward and horizontally from the upper surface of the grille 4242 and is positioned below a portion of the hood 2082. The deflector plate 4254 extends generally vertically and inward relative to the upper plate 4256 and the grille 4242 and is connected to the upper plate 4256 at a live hinge 4258. The pattern of the grille 4242 and the position of the deflector plate 4254 relative to the grille 4242 minimize the possibility that debris or water that might inadvertently flow through the grille 4242 could enter the air intake ducts connected to the powertrain. Conversely, if debris or water flows under the grille 4242 and the hood 2082, the debris or water will contact the outer surface of the deflector plate 4254 and fall vertically downwards out of the vehicle 2, instead of flowing inwards under the hood 2082 and into the intake duct that is in fluid communication with the grille 4242. More specifically, the pattern of the grille 4242 prevents large debris from entering the hood 2082, while the deflector plate 4254 is inside the grille 4242 and obstructs the view of water spray, small debris, and ducts (e.g., CVT intake ducts).

[0261] The hinge assembly 4240 further includes a latch 4260 extending from the deflector plate 4254. The latch 4260 is engaged to the deflector plate 4254 at the live hinge 4262. The latch 4260 includes a slot or opening 4264 configured to receive a strap 4266, which is engaged to the cover ring 4246 and / or the grille 4242. The strap 4266 extends at least partially through the opening 4264 in the latch 4260 and is secured thereto by a clip 4268. In this way, the deflector plate 4254 is engaged to the grille 4242 via the upper plate 4256, the latch 4260, and the strap 4266.

[0262] The deflector plate 4254 is further coupled to the grille 4242 via an arm 4270, which extends from the grille 4242 and / or the shroud 4246 and through an opening 4272 in the deflector plate 4254. The arm 4270 may include a retaining member 4274 configured to extend through the opening 4272 and hook or otherwise retain the arm 4270 on the deflector plate 4254.

[0263] Now for reference Figures 112 to 114 Vehicle 2 may include various accessories. For example, vehicle 2 may include a light strip assembly 4280 coupled to a portion of the cab frame 2028. The light strip assembly 4280 may or may not have a roof for vehicle 2. In one embodiment, and in the absence of a roof on vehicle 2, the light strip assembly 4280 is coupled to frame member 4282, which generally extends between frame members 3072. Illustratively, the light strip assembly 4280 is coupled to a gusset plate 4284, which is coupled to both frame members 3072 and 4282. The gusset plate 4284 may have a generally triangular shape and extend between frame members 3072 and 4282. The gusset plate 4284 includes an opening 4286 configured to receive fasteners 4288 for coupling the light strip assembly 4280 to the cab frame 2028, as further disclosed herein. It should be understood that if the roof is included on vehicle 2, the roof can also be mounted to cab frame 2028 at opening 4286 of gusset plate 4284, so that the roof and light bar assembly 4280 share a common mounting position on cab frame 2028.

[0264] The light strip assembly 4280 comprises at least a light strip 4290, a mounting member 4292, and wiring 4294. The light strip 4290 extends generally along the length of the frame member 4282, and in one embodiment is approximately the same length as the frame member 4282. In an alternative embodiment, the light strip 4290 has a length less than that of the frame member 4282. The light strip 4290 includes an end plate 4296 and a fastener 4298 extending therefrom. The end plate 4296 and the fastener 4298 are received within a recess 4310 of the mounting member 4292, and more specifically, the fastener 4298 extends through an aperture 4300 of the mounting member 4292. The fastener 4298 is engaged with a second fastener 4302 to secure the light strip 4290 to the mounting member 4292.

[0265] Wiring 4294 is electrically coupled to light strip 4290 and extends through a portion of mounting member 4292 and along a portion of frame member 3072 in order to couple with the power supply of vehicle 2.

[0266] Mounting member 4292 may be a die-cast component made of at least a metallic material. Mounting member 4292 includes an aperture 4304 configured to receive a fastener 4288 to support mounting member 4292 and thus the light strip 4290 on the cab frame 2028. Aperture 4304 is positioned along a lower surface 4312 of mounting member 4292. Lower surface 4312 further includes a slot or channel 4306 configured to receive and conceal part of wiring 4294. Isolator 4308 may be positioned adjacent to the cab frame 2028 and mounting member 4294 to minimize vibration transmission to light strip 4290.

[0267] Now for reference Figures 115 to 126 The front suspension assembly 40 is shown in more detail. As described above, the suspension assembly 40 includes an upper alignment or A-arm 280 (…). Figure 126 ), lower alignment or A-arm 282 ( Figures 115 to 116 ) and linear force element (LFE) 284, LFE 284 is shown as a damping spring ( Figure 12 The lower A-arm 282 includes a forward extension 5000 and a rearward extension 5002, which are respectively connected to connectors 374, 376 and 384, 386 to mount the lower A-arm 282 to the frame 20. Figure 8 The forward extension 5000 and the rearward extension 5002 extend generally laterally relative to the longitudinal centerline L. Figure 5 The forward extension 5000 and the rearward extension 5002 are joined together to define the lateral outer portion 5004 of the lower A-arm 282. The outer portion 5004 illustratively includes a ball joint housing 5006 configured to receive the ball joint 394. Figure 13 More specifically, the outer portion 5004 includes a recess 5008 configured to receive a portion of the ball joint housing 5006, such that the ball joint housing 5006 extends outward from the outer portion 5004 to define the outermost lateral extent of the lower A-arm 282. In one embodiment, the ball joint housing 5006 may be a forged component.

[0268] Still referencing Figures 115 to 120 The lower A-arm 282 can be composed of multiple parts. Illustratively, the lower A-arm 282 is composed of an upper stamping part 5010, a lower stamping part 5012, and an upper plate 5014. Unlike the butt joint connection between stamping parts 5010 and 5012, the upper stamping part 5010 is connected to the lower stamping part 5012 at the overlapping side 5016 (in... Figure 120(Best shown in the diagram), such that the upper stamping 5010 and the lower stamping 5012 define a clamshell configuration. In other words, the lower portion of the upper stamping 5010 covers the upper portion of the lower stamping 5012 and contacts the upper portion of the lower stamping 5012 at an overlapping side 5016. The overlapping side 5016 generally extends the full or entire length of the upper stamping 5010 and the lower stamping 5012, and illustratively extends between the ball joint housing 5006 and the connectors 374, 376, 384, 386. The upper stamping 5010 and the lower stamping 5012 may be permanently joined together by weld, adhesive, or any other conventional joining mechanism.

[0269] The lower stamping 5012 defines the lowermost surface of the lower A-arm 282, while the upper stamping 5010 defines at least a portion of the uppermost surface of the lower A-arm 282. More specifically, the upper surface 5018 of the upper stamping 5010 ( Figure 115 The upper surface of the lower A-arm 282 is defined along the length of the lower A-arm 282, which extends generally from the upper plate 5014 to the connectors 374, 376, 384, 386. However, as further described herein, the upper surface 5018 of the upper stamping 5010 at the outer 5004 of the lower A-arm 282 can be vertically positioned below or beneath at least a portion of the upper plate 5014, such that the upper plate 5014 defines the upper surface of the lower A-arm 282 at the outer 5004.

[0270] like Figures 115 to 120 As shown, the upper plate 5014 is configured to be positioned at the exterior 5004 above a portion of the upper surface 5018 of the upper stamping 5010, and can be permanently attached to it by weld, adhesive, or any other conventional coupling mechanism. The upper plate 5014 extends generally from the recess 5020 to the legs 522, 524. The recess 5020 is configured to generally align with the recess 5008 of the upper stamping 5010 and also receives the ball joint housing 5006. Figure 118 As best shown, a portion of the upper stamping 5010 is exposed laterally outward from the upper plate 5014 adjacent to the ball joint housing 5006. Therefore, this layered construction of the ball joint housing 5006, the upper stamping 5010, and the upper plate 5014 allows for a defined welding zone that allows the weld to penetrate all three surfaces during a single welding operation.

[0271] Support legs 522 and 524 extend along a portion of the upper surface of extensions 5000 and 5002, respectively. In this way, upper stamping 5010 and upper plate 5014 together define the uppermost surface of lower A-arm 282, wherein upper stamping 5010 is defined at the uppermost surface of extensions 5000 and 5002, and upper plate 5014 is defined at the uppermost surface of outer portion 5004.

[0272] The upper plate 5014 also includes a sidewall 5026 that extends along a portion of the upper stamping 5010 and downward toward the lower stamping 5012. The upper surface 5028 of the upper plate 5014 includes an opening 5030, which will be described further herein.

[0273] Continue to refer to Figures 115 to 120 The lower A-arm 282 further includes a suspension mounting assembly 5032. The suspension mounting assembly 5032 is defined by a gusset plate 5034, a ball or bearing 5036, and a retaining member 5038 (illustratively, a C-clamp tension member). It should be understood that the component 5036 is not a bushing as conventionally used in other suspension arrangements, but a bearing, because bushings would restrain the movement of impacts.

[0274] The gusset plate 5034 can be forged or machined. The gusset plate 5034 has an opening 5035 (…). Figure 117A and Figure 117B An opening 5035 is configured to receive a bearing 5036 therein. The bearing 5036 is partially secured within the opening 5035 by a small tolerance or interference fit, and thus, the opening 5035 can be dimensionally formed to secure the bearing 5036 by forging the gusset plate 5034. A retaining member 5038 is also configured to secure the bearing 5036 within the opening 5035 of the gusset plate 5035. The bearing 5036 is configured to connect the lower end of the LFE 284 to the lower A-arm 282, as further disclosed herein.

[0275] The gusset plate 5034 is configured to be received within and extend through the opening 5030 of the upper plate 5014. More specifically, the gusset plate 5034 is configured to be positioned at the outer 5004 above a portion of the upper surface 5018 of the upper stamp 5010 and extend through the opening 5030 of the upper plate 5014. Because the upper plate 5014 connects both the upper stamp 5010 and the gusset plate 5034, the upper plate 5014 helps to combine the upper stamp 5010 and the gusset plate 5034 together.

[0276] The opening 5035 of the gusset plate 5032 is exposed and configured to receive fasteners for connection with the LFE 284. The gusset plate 5032 may be permanently connected to the upper stamping 5010 and / or the upper plate 5014 by weld, adhesive or any other conventional connection mechanism. For example, at least a portion of the lower surface 5037 of the gusset plate 5034 may be welded or otherwise permanently connected to the upper surface of the upper stamping 5010, and at least a portion of the transverse surface 5039 of the gusset plate 5034 may be welded or otherwise permanently connected to the upper plate 5014.

[0277] Now for reference Figure 121 and Figure 122 The lower end of LFE 284 is connected to a connector, illustratively to a U-clamp 298, and the connector / U-clamp 298 is connected to a gusset plate 5034, thereby pivotally connecting LFE 284 to the lower A-arm 282. More specifically, U-clamp 298 includes two U-clamp legs 350 having openings 352 configured to align with an opening 5040 of bearing 5036 to receive a fastener 342 passing through it. A second fastener 344 is secured to fastener 342 such that the fastener 342 extends through the openings 352 in the two U-clamp legs 350 and the opening 5040 of bearing 5036, and is partially received within the second fastener 344, thereby removably connecting the lower end of U-clamp 298, and thus LFE 284, to the lower A-arm 282.

[0278] The U-shaped clamp 350 also includes an upper portion 5042, which is coupled to the two U-shaped clamp legs 350 and positioned adjacent to the lower end of the LFE 284. The upper portion 5042 of the U-shaped clamp 350 includes a recess 5044, which is positioned above and adjacent to an opening 5046 defined between the U-shaped clamp legs 350. The opening 5046 is configured to receive the half-shaft 290, and the recess 5044 ensures that a predetermined minimum clearance C is maintained between the half-shaft 290 and the upper portion 5042 of the U-shaped clamp 298 during full compression or rebound of the suspension assembly 40.

[0279] More specifically and reference Figure 124 and Figure 125 , Figure 124 The front suspension 40 is shown at vehicle level (i.e., when stationary or while traveling across generally flat terrain), wherein the front suspension 40 is not in a fully rebounded or fully compressed state. Figure 124In this configuration, it is evident that the clearance C between the upper part 5044 of the U-shaped clamp 298 and the half-shaft 290 is maintained, and the U-shaped clamp 298 does not contact the half-shaft 290. However, even when the front suspension 40 is fully rebounding or compressed, as... Figure 25 As shown, a gap C is also maintained between the upper portion 5044 of the U-shaped clamp 298 and the half-shaft 290, although it is smaller than... Figure 124 The gap C is small. In this way, regardless of the position of the front suspension 40, the U-shaped clamp 298 does not contact the half shaft 290.

[0280] To further maintain clearance C, the gusset plate 5034 includes a stop surface 5048. The stop surface 5048 is a beveled or angled surface angled inward toward the legs 5022, 5024 of the upper plate 5014. The stop surface is configured to allow the U-shaped clamp legs 350 to contact the stop surface before the U-shaped clamp 298 contacts the half-shaft 290. In this way, the stop surface 5048 of the gusset plate 5034 restricts the pivoting movement of the U-shaped clamp 298 to prevent contact with the half-shaft 290.

[0281] Because LFE 284 is connected to the lower A-arm 282, the lower A-arm 282 experiences a load reacted by LFE 284. More specifically, the load from LFE 284 passes through bearing 5036 and enters the spindle 390. Figure 12 Therefore, at least the outer portion 5004 of the lower A-arm 282 is subjected to the load. In this way, through the upper plate 5014 and the upper stamping 5010, the stiffness of the lower A-arm 282 is along the ball joint housing 5006 (connected to the spindle 390) subjected to the load from the LFE 284. Figure 12 The distance 5056 between the suspension mounting assembly 5032 and the suspension mounting assembly 5032 is 5056. Figure 115 and Figure 119 The upper plate 5014 increases the lateral distance from the adjacent ball joint housing 5006 to the suspension mounting assembly 5032. In other words, because the upper plate 5014 spans the lateral distance from the adjacent ball joint housing 5006 to the suspension mounting assembly 5032, the main loads experienced at the front ground engagement member 4 and LFE 284 are more evenly distributed across the lower A-arm 282 via the upper plate 5014, and the upper plate 5014 increases the stiffness at these locations of the main load.

[0282] Now for reference Figure 126 It should be understood that the upper A-arm 280 has a similar structure to the lower A-arm 282, that is, the upper A-arm 280 includes an upper stamping 5050 and a lower stamping 5052 that overlap each other at 5054 and are permanently connected together.

[0283] While the invention has been described as an illustrative design, it may be further modified within the spirit and scope of this disclosure. Therefore, this application is intended to cover any variations, uses, or changes of the invention using its general principles. Furthermore, this application is intended to cover any deviations from this disclosure that are known or customary in the field to which this invention pertains.

Claims

1. A suspension arm for a vehicle, the suspension arm comprising: Part One; and The second part is connected to the first part, and the first part and the second part together define the upper surface of the suspension arm, wherein the first part and the second part together define the location for coupling the shock absorber; The first part includes a first lateral extension and a second lateral extension, and the second part extends along a portion of the first lateral extension and a portion of the second lateral extension of the first part; The second part is connected to the upper surface of the first part.

2. The suspension arm of claim 1, wherein, The second part is connected to the lateral outer portion of the first part.

3. The suspension arm of claim 1 further includes a ball joint housing, and both the first portion and the second portion have a length extending into the ball joint housing.

4. The suspension arm of claim 1, further comprising a mounting assembly for a linear force element, wherein the second portion substantially surrounds the mounting assembly.

5. The suspension arm according to claim 1, further comprising a third portion connected to the first portion.

6. The suspension arm of claim 5, wherein, The third part defines the lowest surface of the suspension arm.

7. The suspension arm of claim 6, wherein, The third part has a height that overlaps with the height of the first part.

8. A method of assembling a suspension arm for a vehicle, the method comprising: Provide the first part; Provide Part Two; Provide a third part; The first portion is permanently coupled to the second portion along the upper surface of the first portion, wherein the first portion includes a first lateral extension and a second lateral extension, the second portion extends along a portion of the first lateral extension and the second lateral extension of the first portion, and wherein the first portion and the second portion define a coupling location for a shock absorber. Align the upper portion of the third part with the lower portion of the first part; as well as The first portion is permanently connected to the third portion along the lower portion of the first portion.

9. The method of claim 8, wherein, The first portion and the second portion define the uppermost surface of the suspension arm.

10. The method of claim 8, further comprising: Suspension brackets are provided; and The suspension bracket is permanently connected to the first part and the second part.

11. The method of claim 10, further comprising positioning the suspension bracket as an opening extending through the second portion.

12. The method according to claim 8, wherein, Providing a first part includes stamping the first part, and wherein providing a third part includes stamping the third part.

13. The method according to claim 12, wherein, Permanently connecting the first portion to the second portion includes welding the first portion to the second portion, and wherein permanently connecting the first portion to the third portion includes welding the first portion to the third portion.

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