CHF Chassis
CHF Chassis
Chassis
Chapter Outline
• Chassis
• Suspension
• Steering
• Brake
• Tire
• Disc Wheel
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Frequent Service Job Course Chassis
Chassis
Chassis
Along with the exterior, interior, and engine, the chassis makes up
a vehicle. It manages the driving, turning, and stopping function.
1. Suspension
Physically supports the axles to ensure a better ride.
Front suspension
Rear suspension
2. Steering
Changes the direction of travel of the vehicle.
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Frequent Service Job Course Chassis
3. Brakes
Decelerate or stop the vehicle.
Foot brakes
Parking brakes
(1/1)
Suspension
Suspension
The suspension system joins the wheels to the body or the frame
in order to support the vehicle physically.
Front suspension
Rear suspension
Spring
Shock absorber
Stabilizer bar
Ball joint
(1/2)
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Frequent Service Job Course Chassis
Shock Absorbers
Piston
Valve
Orifice
Spring
Shock absorber
REFERENCE:
Types of shock absorbers
Classification by operation
Classification by construction
Classification by working medium
(1/1)
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Classification by operation
Single-action shock absorber
Type that damps the vibration of the spring when the shock
absorber extends, but doesn't damp it when it shrink.
Multi-action shock absorber
Type to damp the vibration of the spring when the shock absorber
both extends and shrinks.
Orifice
Valve
Fluid
Classification by construction
Mono-tube shock absorber
Type with only one cylinder (no reservoir)
Twin-tube shock absorber
Type with a cylinder consisting of a working chamber (inner
cylinder) and a reservoir chamber (outer cylinder).
Reservoir chamber
Working chamber
Air
Fluid
Valve
(1/1)
Valve
Low-pressure gas
Fluid
Free piston
High-pressure gas
(1/1)
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Frequent Service Job Course Chassis
ECU
Absorber control switch
Sensors
Absorber control actuator
Shock absorber
Starting-off
Strong damping force to stabilize the vehicle's posture.
Normal driving
Weak damping force to give a comfortable ride.
Turning
Strong damping force to stabilize the vehicle.
High-speed driving
Medium dampening force to give both a comfortable ride and
driving stability.
Braking
Strong dampening force to stabilize the vehicle.
(1/1)
Ball Joint
Ball joints bear vertical as well as horizontal loads, and also act as
pivots for the steering knuckles when the steering wheel is turned.
Stud
Boot
Seat
Housing
Rubber Cushion
(1/1)
Stabilizer Bar
When the vehicle leans and the tires sink to one side, the
stabilizer bar is twisted and operates as a spring, which lifts up the
tires) the body on the sinking side.
In case the tires on both sides sink equally, the stabilizer bar does
not operate as a spring because it is not twisted.
Stabilizer bar
(1/1)
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Frequent Service Job Course Chassis
Wheel Alignment
Camber
Steering axis (Kingpin) inclination
Caster
Turning radius
Toe angle (Toe-in and Toe-out)
HINT:
Both front and rear wheels of vehicles are aligned, with the
exception of the wheels of rear rigid axle suspension FR vehicles.
Camber
This is the angle of the inclination of the wheel as viewed from the
front of the vehicle.
θ a : Camber angle
This angle is formed by the centerline of the wheel and the line
that extends perpendicularly from the ground.
θ b: Kingpin angle
This is the inclination of the kingpin axle.
L: Kingpin offset
This is the distance measured along the road surface between the
tire centerline and the point at which the extended line from the
kingpin axle intersects with the road surface.
HINT:
The kingpin angle is the line that links the upper ball joint and the
lower ball joint, and the rotational centerline of the front wheel
when the steering wheel is turned.
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Frequent Service Job Course Chassis
Caster
This is the inclination of the kingpin axle, which dampens the
impact from the tires.
θ c : Caster angle
This is the angle between the kingpin axle and the plumb line.
This angle creates a force to return the wheels to the straightline
position, thus enabling the vehicle to track straight.
L : Caster trail
This is the distance between the ground contact center of the tire
and the ground contact point of the line that extends from the
kingpin axle.
The ability of the vehicle to drive in a straight line increases
according to the caster trail distance.
Turning radius
This is the turning angle of either front wheel when the steering
wheel is turned.
The inner and outer front wheels turn at different angles so that
they can draw circles around the same center, in order to ensure
the cornering performance of the vehicle.
When the vehicle is viewed from the top, both front and rear
wheels generally point inward. This condition is called "toe-in",
and it helps the vehicle track straight. It is called 'toe-out', when
the front wheels point outward.
Toe in
Toe out
(1/1)
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Frequent Service Job Course Chassis
Steering
Steering
Rack-and-pinion type
Changes the rotational movement of the steering wheel into the
left or right movement of steering rack. The construction is simple
and lightweight. The steering is solid, and the steering wheel
response is very sharp.
Steering wheel
Steering main shaft & column tube
Steering gear
Steering rack housing
Pinion
Rack
(1/1)
REFERENCE:
Recirculating-ball type
There are many balls between the worm shaft and the nut at the
sector shaft.
Steering wheel
Steering main shaft & column tube
Steering gear
Steering linkage
Steel balls
Ball nut
Sector shaft
Worm shaft
(1/1)
Brakes
Brakes
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Frequent Service Job Course Chassis
Foot brakes
Parking brakes
(1/1)
Foot Brakes
Foot brakes are used to control vehicle speed and stop the
vehicle.
Generally, disc brakes are used on the front wheels, and disc
brakes or drum brakes are used on the rear wheels.
Brake pedal
Brake booster
Master cylinder
Proportioning valve (P valve)
Disc brake
Drum brake
(1/3)
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Frequent Service Job Course Chassis
Brake pedal
Parts controlled by the force of the driver's foot. This force
becomes converted into hydraulic pressure, which acts on the
brake system.
The strength of the braking force is determined by the amount of
pedal effort that is applied by the driver.
It is necessary to inspect the brake pedal free play, height, and the
pedal reserve distance in maintenance.
Brake booster
Device to boost the force that acts on the master cylinder in
accordance with the amount of pedal effort that is applied by the
driver.
The vacuum from the engine intake is used as the source of boost
energy.
Master cylinder
Parts to convert the driver's pedal effort into the hydraulic
pressure.
Reservoir It consists of a reservoir that stores the brake fluid and a cylinder
Cylinder that generates hydraulic pressure.
To front brakes The master cylinder converts the driver's pedal effort into
To rear brakes hydraulic pressure. The hydraulic pressure is then applied to the
disc brake calipers of the front and rear brakes, and to the wheel
cylinders of the drum brakes.
Maintenance items include the replacement of the brake fluid.
(3/3)
Disc Brakes
Push the disc brake pad against the rotation disc brake rotor with
the wheels, and create friction. Controls the wheel rotations by
friction.
Before operation
During operation
(1/3)
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Frequent Service Job Course Chassis
REFERENCE:
Types of disc brake caliper
(1/1)
Anti-squeal shim
Prevents unusual noise as the brake pad vibrates at the time of
braking.
(2/3)
Solid type
Ventilated type
With drum type
(3/3)
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Frequent Service Job Course Chassis
Drum Brakes
A brake drum rotates together with the wheel. The brake shoes
press against the drum from the inside. This friction controls the
rotation of the wheel.
It is necessary to inspect the brake drum and brake lining.
HINT:
The brake shoes press against the rotating drum from the inside
to get braking power. When pressed in the same direction as the
drum rotates, the shoes make inroads into the rotational direction
by the friction with the drum. As a result, the friction power
increases, which is called self-energizing action.
Wheel Cylinder
There is a piston, which the rubber cup is attached, in the cylinder. This piston transmits the hydraulic pressure to the brake shoe
from the master cylinder, and presses against the brake lining.
Brake Drum
Drums to rotate with the wheels.
Piston
Parts that get the hydraulic pressure from the master cylinder and press the brake shoe into the brake drum.
Piston Cup
The piston cup is the rubber part that keeps the oilsealed between the wheel cylinder and piston.
(1/1)
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Frequent Service Job Course Chassis
REFERENCE:
Types of the drum brake
Leading-and-trailing type
Two-leading type
Uni-servo type
Duo-servo type
Red arrow:
rotational direction of the wheel
Pink arrow:
direction that the piston moves
The diagram on the left indicates the color of the brake shoe.
Leading shoe: orange
Trailing show: blue
(1/1)
Parking Brakes
Rear Brake
Press the brake shoe (disc brake pad) against the drum (disc
rotor) to fix the vehicle in position.
(1/1)
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Frequent Service Job Course Chassis
REFERENCE:
Parking brake lever types
Lever type
Mainly used in passenger and commercial vehicles.
Stick type
Used in some commercial vehicles.
Pedal type
Used in some passenger and high-grade vehicles. Nowadays the
release is operated with the pedal.
Release lever
Pedal
(1/1)
REFERENCE:
Parking brakes body types
Brake shoe
Shoe lever
Piston
Disc brake pad
Disc brake rotor
Parking brake cable
(1/1)
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Frequent Service Job Course Chassis
Tires
Tires
Tread
An outer layer of the tire that protects the carcass and prevents
wear and cuts.
Belt (Rigid Breaker)
A reinforcement belt that is affixed circumferentially between
the tread and the carcass.
Carcass (Cross Plies)
Forms the skeletal structure of the tire and forms the tire.
Inner Liner
A rubber layer that is equivalent to a tube, it is affixed to the
inside wall of the tire.
Bead Wire
Secures the tire on the rim.
Radial tire
Compared to a bias tire, its tread deformation is smaller. Thus, it
has a better grip and cornering performance. Because of its
higher tread rigidity, it is more susceptible to transmitting the road
shocks, and results in a slightly poorer ride comfort.
Bias Tire
Compared to a radial tire, this tire gives a softer ride, but its
cornering performance is slightly inferior.
(1/1)
REFERENCE:
Types and Features of Tires
Tubed tire
Contains a tube that is inflated with air.
Tubeless tire
Has a special rubber layer called an "inner liner" instead of a tube.
Low-profile tire
"Profile" pertains to the contour of the side of the tire, and a "low-
profile" tire has a low cross section with a maximum aspect ratio
*
of 60% .
The sidewalls are low, and the tread deformation when turning is
small, so the cornering force is greatly improved.
*: Aspect ratio = H/W x 100%
Run-flat tire
Tube This tires' sidewalls contain reinforced rubber, so even if a vehicle
Valve equipped with this tire has a puncture while driving, and the air
Inner liner pressure drops to zero, it can continue to travel another 100 km
Side rubber reinforcement (62 mile) at a maximum speed of 60 km/h (37 mph).
(1/1)
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Frequent Service Job Course Chassis
Tire height
Tire width
Wheel rim diameter
Tire external diameter
(1/2)
REFERENCE:
How to read the tire size
1. Radial-ply tire
2. International standardization organization(ISO) tire coding
system
3. Bias-ply tire
4. Compact space tire(T type tire)
1. Radial-ply tire
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Frequent Service Job Course Chassis
3. Bias-ply tire
(1/1)
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Frequent Service Job Course Chassis
Aspect ratio
The ratio of the height of the cross section of the tire to the width
(which is rendered 100) is indicated as a percentage (%).
(2/2)
Disc Wheels
Disc Wheels
(1/2)
(2/2)
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Frequent Service Job Course Chassis
REFERENCE:
How to read the wheel size
(1/1)
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Frequent Service Job Course Chassis
Exercises
Use the Exercises to check your level of understanding for the material in this Chapter. After answering each Exercise,
you can use the reference button to check the pages related to the current question. When you get a wrong answer,
please return to the text to review the material and find the correct answer. When all questions have been answered
correctly, you can go to the next Chapter.
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Frequent Service Job Cource Chassis
Exercise
Question-1
Select the role of each part shown in the illustrations below from statements a) to d).
1. 2.
3. 4.
Answer: 1. 2. 3. 4.
Question-2
The following illustrations are of the rack-and-pinion type steering device. Select the name of each part from the word
group below.
a) Pinion
b) Steering gear
c) Steering rack housing
d) Rack
Answer: 1. 2. 3. 4.
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