I Unit Maintenance, operation and components of

Chassis group
Name Rut
Career(s) Automotive Mechanics Heavy Machinery Semester Autumn 2023
Code / subject Machinery Chassis Group Section
Teacher Date
3°1b Study guide of Machinery Chassis Group 2023
Genaro Rivera Gamboa
Air suspension
Unit I: Maintenance, operation, and components of the Chassis group
EXPECTED LEARNING OUTCOMES
1.1.- Verify the operation of different systems of the chassis group according to the work procedure, manual of
manufacturer and current regulations. (Integrated generic competence Critical Thinking).
EVALUATION CRITERIA
1.1.1.- Explain the operating principles of the different systems in the chassis group.
1.1.2.- Recognizes the systems, subsystems, and components of the chassis group.
1.1.3.- Use guidelines, plans, technical procedures.
1.1.4.- Applies the safety protocols and regulations for the execution of procedures in the workshop activity.
1.1.5.- Visually inspect and use precision tools and instruments on the systems and components of the chassis group.
1.1.6.- Measure with specific tools, operating parameters of the chassis group components.
MINIMUM MANDATORY CONTENTS
Operating principles and components of: hydraulic and pneumatic braking systems.
Principles of operation and components of: pneumatic and mechanical suspension systems.
Operating principles and components of: steering systems with Orbitrol.
Precision tools and instruments: Dial gauge, caliper, micrometer, calibrated gauges, torque wrench.
MINIMUM MANDATORY CONTENTS
Principles of operation and components of pneumatic and mechanical suspension.

Air suspension
The air suspension is currently the most commonly used in the rear of trucks and cargo vehicles, including
certain types of buses, tractor trucks or semi-trailers.

The main reason is that this type of suspension ensures a more comfortable and smooth ride regardless of the level of
load that the vehicle transports. This is explained by the use of compressed air within the chambers located between the axle and the
truck chassis, in order to absorb the different types of irregularities in the terrain and make them less perceptible
possible both for the driver and occupants of the vehicle as well as for the rear cargo, making it not exposed to
Continuous sudden movements or swaying.

It is probably the most flexible type of suspension in terms of heavy vehicles, able to be adjusted in height.
manually or automatically, depending on the type of terrain to be traveled, its condition, and the type of
driving.

Main advantages of pneumatic suspension for cargo vehicles

More comfort in handling the load in the case of tractor trucks due to the simple coupling system and
unhooking of the trailer.
Greater reliability and safety when transporting fragile products thanks to the uniform absorption of irregularities.
land and a lower level of vibration in the vehicle's loading area during driving.
It allows transporting a higher level of load while keeping the distance from it to the road uniform throughout.
moment.
A higher level of security regarding braking control based on the load carried.
Its operation and implementation ensure better preservation of the roads, achieving that the weight of the truck
and the transported load has a lower impact on the asphalt during transportation.

Characteristics
It is composed of air chambers similar to tires controlled by leveling valves that ensure the height of
vehicle independent of the load.
With the increase in load, there is an operation of the level valve, releasing air into the chambers, consequently,
an increase in the internal pressure of them, thus returning the vehicle to its original position.
Better comfort compared to metallic suspension due to low vibration and natural frequency. Presents less
reaction of the tires to the pavement.
Low maintenance with the ease of changing them.
Another type of suspension for trucks and heavy vehicles, rolling shirt.

After pneumatic suspension, the most common type of suspension for these vehicles is mechanical suspension.

In this case, we talk about a simpler type of suspension that, instead of basing its operation on air, grounds it
in various mechanical elements, which would be responsible for counteracting the irregularities of the terrain, affecting it the least
possible to the quality of driving and the safety of the load.

The main components of mechanical suspension systems are:

Leaf springs: They are the basis of this type of suspension and are responsible for smoothing out the impacts caused by irregularities.
from the road, extending the life of the vehicle chassis. They are made up of a series of steel plates with a certain curvature.

Shock absorber: It is responsible for controlling the movement resulting from the absorption of the irregularities of the asphalt.
struts, so that this does not affect the grip and stability of the wheels. Those used in this type of systems
The suspension is hydraulic with a telescopic drive.

The stabilizer bar: As its name indicates, it is responsible for ensuring the stabilization of the vehicle's suspension.
situations that could create some imbalance in the external parts of the axes, such as curves, braking
or potholes. They are always positioned perpendicular to the axis of the truck to achieve the stabilization of the vehicle.
longitudinal manner and neutralize the possible lateral sway that may occur in the curves.

With these two previous components, we could say that they are responsible for absorbing the irregularities of the
road so that they affect the truck as little as possible, the stabilizer bar ensures its balance in different
situations that may occur during driving. A fundamental component considering the size and the
weight of this type of vehicles.
Air Suspension: How It Works, Components.

The air suspension supports the load on each axle with a pressurized air bag very similar to a high-pressure balloon.
Modern airbags are constructed using the same process as a tire, using high-strength cords.
which are then wrapped in rubber. These units are very durable in service and have a proven lifespan of many years.

Air suspension
The main difference between a traditional shock absorber is that they have a damping mechanism adjusted to a certain
feeling of control over the suspension, while an air suspension system uses an air compressor in
combination with air struts (supports) and air suspension bags to control the feel of the suspension.

Function
Instead of the metal spring mechanism, the strong rubber bags act as air containers. The bags are
they connect to an air compressor and an air tank.

The compressor does the work of inflating and deflating the bags, which is how the car goes up and down. The resulting effects are a
smoother driving and greater versatility in performance.
These systems come with a control unit that is located inside the car to give the driver total control over it.
system.

Components of the air suspension

A vulcanized rubber air damper on each wheel.

An air compressor, which is usually found in the trunk or under the hood.
A compressed air storage tank can be included, which stores air at ~150 psi (1000 kPa), note (1
psi=6.89kPa).
A valve block that directs the air from the storage tank to the four air bellows through a series
of solenoids, valves, and many O-rings.
A series of 6 mm air tubes that channel air through the system (mainly from the tank of
storage up to the air cushions through the valve block.
A dryer air reservoir that contains desiccant.
Ideally at the 4 corners of the vehicle, typically based on resistive contact detection to provide a reference.
absolute height for each corner of the vehicle.

Components of the front air suspension

1.- Reaction bar

2.- Stabilizer
3.- Shock absorber
4.- Crossbar
5.- Air bellows

Components of rear air suspension

1.- Console
2.- Reaction bar
3.- Air spring beam
4.- Stabilizer
5.- Air Blower
6.- Bellows Plate
7.- Shock absorber
V-Bar
Types of pneumatic suspension
3 types of pneumatic suspensions for vehicles:

Double air suspension

These types of suspensions are mainly used in cars with front suspension. These suspension systems
they can support more weight compared to other suspensions and are therefore generally used in heavy vehicles.
The suspension is called that because the two airbags are connected by a short stroke and the design resembles a clock.
of sand.

Conical sleeve pneumatic suspension

Conical bag pneumatic suspensions are used in vehicles that have a rear suspension and require a
smoother driving, like luxury cars. These systems are conical and provide a greater adjustment in height.
the suspension.

Pneumatic suspension of roller shirt

These types of pneumatic suspension systems are used in vehicles with rear suspension. They are used in cars that
they require a more refined handling, like sports cars.

Parts of a bellows

1.-Bolt
2.-Combination bolt
3.-Blind nut
4.-Air intake
5.- Closing plate
6.-Bladder or Rubber
7.-Internal stopper (optional)
Piston
9.-Piston pin
10.-Retaining ring

Volvo bellows
1.- Connection from the level valve
2.-Fixing screw
3.-Support plate
4.-Rubber bumper
5.- Bellows
6.- Embolism

Failures of the air suspension

Toe nail
Concave flange plate
Loose internal top
Hole in the sidewall area of the tire (serpentine)
Hole in the area of the flange plate joint
Leaks around the blind nuts
Broken or defective shock absorber
Defective leveling valve
Overloaded vehicle
Pressure regulator with very low position
Wrong airbag (too high)
On extension
Possible causes
Broken or incorrect shock absorber
Defective regulator valve
Rolling position too high
Defective upper cover (lift)
Incorrect airbag (too short)

Aspect or state
Convex rim plate, especially around blind nuts or
bolts
Rubber bellows separated from the flange plate
Leaks in blind nuts or bolts
Escape in the extreme closure (reversible shirt)
Loose waist tire in a serpentine style

Circle segments
Aspect or condition
Circle bellows cut at the edge plate joint
Bellows cut in a circle at the piston joint (reversible sleeve style)
Possible causes
High pressure, fully extended for long periods of time
Impact in compressed position