Note: Descriptions are shown in the official language in which they were submitted.
VEHICLE
[0001] The present application is a continuation-in-part of U.S. Patent
Application
Serial No. 16/861,859, filed April 29, 2020, and entitled "VEHICLE," which
claims priority
to U.S. Provisional Patent Application Serial No. 62/840,654, filed April 30,
2019, and
entitled "VEHICLE," the complete disclosures of which are expressly
incorporated by
reference herein.
FIELD OF THE DISCLOSURE
[0002] The present invention relates to side-by-side vehicles and all-
terrain
vehicles.
BACKGROUND OF THE DISCLOSURE
[0003] Generally, all-terrain vehicles ("ATVs") and utility vehicles
("UVs") are
used to carry one or two passengers and a small amount of cargo over a variety
of
terrains. Due to increasing recreational interest in ATVs, specialty ATVs,
such as those
used for trail riding, racing, and cargo hauling have entered the market
place. Most
ATVs include seating for up to two passengers which are either seated side-by-
side or
with the passenger positioned behind the driver of the ATV. Side-by-side ATVs,
in which
the driver and passenger are seated beside each other on laterally spaced
apart seats,
have become popular because of the ability to allow the passenger to share the
driver's
viewpoint.
SUMMARY OF THE DISCLOSURE
[0004] In one embodiment of the present disclosure, a suspension arm for a
vehicle comprises a first portion and a second portion coupled to the first
portion. The
first portion and the second portion together define an upper surface of the
suspension
arm.
[0005] In a further embodiment of the present disclosure, a suspension
assembly
for a vehicle comprising an alignment arm comprising a mounting assembly
having a
bearing plate and a bearing member. The bearing member is removably coupled
within
1
Date Regue/Date Received 2022-11-03
a portion of the bearing plate. The suspension assembly further comprising a
linear
force element movably coupled to the alignment arm at the bearing member.
[0006] In another embodiment of the present disclosure, a suspension arm
for a
vehicle comprising an upper portion and a lower portion. An upper extent of
the lower
portion overlaps a lower extent of the upper portion to define overlapping
sides of the
upper and lower portions. The upper portion is coupled to the lower portion at
the
overlapping sides.
[0007] In yet another embodiment of the present disclosure, a method of
assembling a suspension arm for a vehicle, the method comprising providing a
first
portion, providing a second portion, providing a third portion, permanently
coupling the
first portion to the second portion along an upper surface of the first
portion, and
permanently coupling the first portion to the third portion along a lower
extent of the first
portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a front left perspective view of the vehicle of the
present
invention without the body panels;
[0009] FIG. 2 is a right rear perspective view of the vehicle of FIG. 1;
[00010] FIG. 3 is a left side view of the vehicle of FIG. 1;
[00011] FIG. 4 is a right side view of the vehicle of FIG. 1;
[00012] FIG. 5 is a top view of the vehicle of FIG. 1;
[00013] FIG. 6 is a front view of the vehicle of FIG. 1;
[00014] FIG. 7 is a rear view of the vehicle of FIG. 1;
[00015] FIG. 8 is a front left perspective view of the frame of the
vehicle of FIG. 1;
[00016] FIG. 9 is a rear right perspective view of the frame shown in FIG.
8;
2
Date Regue/Date Received 2022-11-03
[00017] FIG. 10 is a front left perspective view of the front suspension
of the
vehicle;
[00018] FIG. 11 is a left side view of the front suspension of the
vehicle;
[00019] FIG. 12 is a view similar to that of FIG. 10, having removed the
frame;
[00020] FIG. 13 is a rear perspective view of the suspension as shown in
FIG. 12;
[00021] FIG. 14 is an enlarged view of the front right side suspension;
[00022] FIG. 15 is a partially exploded view of the suspension of FIG. 14;
[00023] FIG. 16 shows a floating rotor design for the vehicle;
[00024] FIG. 17 is a left front perspective view of the front removable
frame
portion;
[00025] FIG. 18 is a partially exploded view of the front removable frame
portion of
FIG. 19;
[00026] FIG 19 is a front left perspective view of the final drive removed
from the
front frame of FIG. 18;
[00027] FIG. 20 is a bottom view of the vehicle showing the rear
suspension;
[00028] FIG. 21 is a right front perspective view of a portion of the rear
suspension;
[00029] FIG. 22 shows an exploded view of the rear suspension of FIG. 21;
[00030] FIG. 23 is a front left perspective view of the powertrain of the
vehicle;
[00031] FIG. 24 is a right rear perspective view of the engine;
[00032] FIG. 25 is a right rear perspective view of the engine oil pan and
lubrication system;
3
Date Regue/Date Received 2022-11-03
[00033] FIG. 26 is a view similar to that of FIG. 25 showing the front
scavenge
pump exploded away from the oil pan;
[00034] FIG. 27 is a cross-sectional view through lines 27-27 of FIG. 25;
[00035] FIG. 28 is a cross-sectional view through lines 28-28 of FIG. 25;
[00036] FIG. 29 is a left-hand side view of the engine mounts;
[00037] FIG. 30 is a left rear perspective view of the engine mounts;
[00038] FIG. 31 is similar to that of FIG. 30, showing the engine and
engine
mounts in an exploded manner away from the frame;
[00039] FIG. 32 is a right-hand side view of the engine mounts;
[00040] FIG. 33 is a right rear perspective view of the engine mounts;
[00041] FIG. 34 is a left front perspective view of the transmission
coupled to the
front final drive;
[00042] FIG. 35 is a rear perspective view of the transmission shown in
FIG. 34;
[00043] FIG. 36 is a cross-sectional view through lines 36-36 of FIG. 34;
[00044] FIG. 37 is an exploded view of the slip clutch portion of the
transmission;
[00045] FIG. 38 shows a diagrammatical flow chart showing the torque
control
model;
[00046] FIG. 39 is a front perspective view of the continuously variable
transmission (CVT) of the powertrain shown in FIG. 23;
[00047] FIG. 40 is the inner housing of the CVT shown with the drive and
driven
clutches removed;
[00048] FIG. 41 is a cross-sectional view through lines 41-41 of FIG. 39;
[00049] FIG. 42 shows a coolant level switch for the coolant bottle;
4
Date Regue/Date Received 2022-11-03
[00050] FIG. 43 is a front perspective view of the utility bed of the
vehicle;
[00051] FIG. 44 shows a right-side view of the passenger seat and fuel
tank
configuration;
[00052] FIG. 45 shows a top view of the seat shown in FIG. 44;
[00053] FIG. 46 shows an enlarged view of the rear cab frame support area;
[00054] FIG. 47 is a fragmentary enlargement of the right rear portion of
the cab
frame support area shown in FIG. 46;
[00055] FIG. 48 is a cross-sectional view through lines 48-48 of FIG. 46;
[00056] FIG. 49 is a view showing the fully assembled taper lock fitting;
[00057] FIG. 50 shows an enlarged portion of the area denoted in FIG. 46;
[00058] FIG. 51 shows a left front perspective view of an alternative
front frame
portion to that of the front removable frame portion of FIG. 17;
[00059] FIG. 52 is a partially exploded view of the front frame portion of
FIG. 51;
[00060] FIG 53 is a front left perspective view of the final drive removed
from the
front frame portion of FIG. 51;
[00061] FIG. 54 is a left side view of front frame portion of FIG. 53;
[00062] FIG. 55 is a right side view of front frame portion of FIG. 53;
[00063] FIG. 56 is a left front perspective view of an alternative frame
of the
vehicle of Fig. 1;
[00064] FIG. 56A is a left front perspective view of a portion of the
frame of Fig.
56;
[00065] FIG. 57 is a right rear perspective view of the frame of Fig. 56;
Date Regue/Date Received 2022-11-03
[00066] FIG. 58 is a left front perspective view of the frame of Fig. 56
coupled to
an alternative cab frame;
[00067] FIG. 59 is a detailed perspective view of a tie-down member of the
frame
of Fig. 56;
[00068] FIG. 60 is a detailed perspective view of a tie-down member of the
frame
of Fig. 57;
[00069] FIG. 61 is a left front perspective view of the cab frame of Fig.
58;
[00070] FIG. 62 is a left rear perspective view of an underside of the cab
frame of
Fig. 61;
[00071] FIG. 63 is a left rear perspective view of a support area of a
rear portion of
the frame of Fig. 57 configured to support a utility bed, a portion of an air
intake, a
portion of an exhaust, and a portion of a cooling system;
[00072] FIG. 64 is a left rear perspective view of the support area of
Fig. 63;
[00073] Fig. 65 is an exploded view of the support area of Fig. 64;
[00074] Fig. 66 is a left rear perspective view of an underside of the
support area
of Fig. 63;
[00075] Fig. 67 is a right rear perspective view of the underside of the
support area
of Fig. 66;
[00076] Fig. 68 is an exploded view of the support area of Fig. 67;
[00077] Fig. 69 is a left front perspective view of a portion of an
alternative front
suspension of the vehicle of Fig. 1;
[00078] Fig. 70 is an exploded view of a lower portion of a linear force
element of
the front suspension of Fig. 69 and a clevis of the linear force element;
[00079] Fig. 71 is a right rear perspective view of an alternative front
braking
system of the vehicle of Fig. 1;
6
Date Regue/Date Received 2022-11-03
[00080] Fig. 72 is a left front perspective view of a brake disc and brake
caliper of
the front braking system of Fig. 71;
[00081] Fig. 73 is an exploded view of the brake caliper and brake pads of
the
front braking system of Fig. 72;
[00082] Fig. 74 is a right rear perspective view of an alternative rear
braking
system of the vehicle of Fig. 1;
[00083] Fig. 75 is a left front perspective view of an alternative rear
suspension of
the vehicle of Fig. 1;
[00084] Fig. 76A is a left front perspective view of a toe link coupling
of the rear
suspension of Fig. 75;
[00085] Fig. 76B is an exploded view of the toe link coupling of Fig. 76A;
[00086] Fig. 76C is a cross-sectional view of the toe link coupling of
Fig. 76A,
taken along line 76C-76C of Fig. 76A;
[00087] Fig. 77A is a left front perspective view of a trailing arm of the
rear
suspension of Fig. 75;
[00088] Fig. 77B is an exploded view of the trailing arm of Fig. 77A;
[00089] Fig. 78 is a cross-sectional view of the trailing arm of Fig. 77A
taking along
line 78-78 of Fig. 77A;
[00090] Fig. 79 is a perspective view of an arc spring assembly of the
powertrain
of the vehicle of Fig. 1;
[00091] Fig. 80 is a perspective view of the arc spring assembly coupled
to a
crankshaft of the engine of the powertrain of Fig. 79;
[00092] Fig. 81 is an exploded view of the arc spring assembly of Fig. 79;
[00093] Fig. 82 is a perspective view of an arc spring damper assembly of
the arc
spring assembly of Fig. 79;
7
Date Regue/Date Received 2022-11-03
[00094] Fig. 83 is a cross-sectional view of the arc spring damper
assembly of Fig.
82, taken along line 83-83 of Fig. 82;
[00095] Fig. 84 is a cross-sectional view of the arc spring damper
assembly of Fig.
82, taken along line 84-84 of Fig. 82;
[00096] Fig. 85 is a left front perspective view of a front drive and
mounting
assembly of the frame of Fig. 56;
[00097] Fig. 86A is an exploded view of the front drive and mounting
assembly of
Fig. 85;
[00098] Fig. 86B is a right rear perspective view of the front drive and
mounting
assembly of Fig. 85;
[00099] Fig. 87A is a left front perspective view of a rear drive and
mounting
assembly of the frame of Fig. 57;
[000100] Fig. 87B is an exploded view of the rear drive and mounting
assembly of
Fig. 87A;
[000101] Fig. 88 is a perspective view of a breather tube of the powertrain
of the
vehicle of Fig. 1;
[000102] Fig. 89 is a further perspective view of the breather tube of Fig.
88;
[000103] Fig. 90 is a cross-sectional view of a portion of the breather
tube of Fig.
88, taken along line 90-90 of Fig. 88;
[000104] Fig. 91 is an exploded view of the breather tube of Fig. 89;
[000105] Fig. 92 is a cross-sectional view of a check valve of the breather
tube of
Fig. 89 when the vehicle of Fig. 1 is in a tip- or roll-over condition;
[000106] Fig. 93 is a cross-sectional view of the check valve of Fig 92
when the
vehicle of Fig. 1 is in an upright position on a ground surface;
8
Date Regue/Date Received 2022-11-03
[000107] Fig. 94 is a right rear perspective view of air intake bezels of
the vehicle of
Fig. 1;
[000108] Fig. 95 is a perspective view of the air intake bezel of Fig. 94;
[000109] Fig. 96 is an exploded view of the air intake bezel and a bezel
cover;
[000110] Fig. 97 is a right rear perspective view of an exhaust of the
vehicle of Fig.
1;
[000111] Fig. 98 is a right rear perspective view of a muffler of the
exhaust of Fig.
97;
[000112] Fig. 99 is a cross-sectional view of an outlet portion of the
exhaust, taken
along line 99-99 of Fig. 98;
[000113] Fig. 100 is a perspective view of a coolant bottle of the vehicle
of Fig. 1;
[000114] Fig. 101 is a left rear perspective of the frame of Fig. 57 and a
fuel tank
with a vent line;
[000115] Fig. 102 is a right rear perspective view of a shifting assembly
for a
shiftable transmission of the vehicle of Fig. 1;
[000116] Fig. 103 is an elevational view of a portion of the shifting
assembly and the
shiftable transmission of Fig. 102;
[000117] Fig. 104 is a left front perspective view of a panel within a
seating area of
the vehicle of Fig. 1;
[000118] Fig. 105 is an exploded view of the panel of Fig. 104;
[000119] Fig. 106 is a perspective view of an air intake grille and a
portion of a hood
of the vehicle of Fig. 1;
[000120] Fig. 107 is an underside view of the hood and the air intake
grille of Fig.
106;
9
Date Regue/Date Received 2022-11-03
[000121] Fig. 108 is an exploded view of the hood and the air intake grille
of Fig.
107;
[000122] Fig. 109 is a perspective view of the air intake grille and a
hinge assembly;
[000123] Fig. 110 is a further perspective view of the air intake grille
and a hinge
assembly of Fig. 109;
[000124] Fig. 111 is another perspective view of the air intake grille and
a hinge
assembly of Fig. 110;
[000125] Fig. 112 is a right front perspective of a lightbar assembly
coupled to a
portion of the cab frame of the vehicle of Fig. 1;
[000126] Fig. 113 is a perspective of the mounting of the lightbar assembly
to the
cab frame of Fig. 112;
[000127] Fig. 114 is a perspective view of an underside of a mounting
member of
the lightbar assembly of Fig. 112;
[000128] Fig. 115 is a rear perspective view of the lower suspension arm of
Fig. 12;
[000129] Fig. 116 is a front perspective view of the lower suspension arm
of Fig.
115;
[000130] Fig. 117A is an exploded view of the lower suspension arm of Fig.
116;
[000131] Fig. 117B is a further exploded view of the lower suspension arm
of Fig.
117A;
[000132] Fig. 118 is a perspective view of a ball joint housing of the
lower
suspension arm of Fig. 115;
[000133] Fig. 119 is a cross-sectional view of the lower suspension arm of
Fig. 116,
taken along line 119-119 of Fig. 116;
[000134] Fig. 120 is a cross-sectional view of the lower suspension arm of
Fig. 116,
taken along line 120-120 of Fig. 116;
Date Regue/Date Received 2022-11-03
[000135] Fig. 121 is a front perspective view of the lower suspension arm
of Fig.
116 coupled to the clevis for the linear force element of the suspension
assembly of Fig.
12;
[000136] Fig. 122 is an exploded view of the lower suspension arm and
clevis of
Fig. 121;
[000137] Fig. 123 is a perspective view of the clevis is Fig. 122;
[000138] Fig. 124 is a front view of the lower suspension arm of Fig. 116
and a
cross-sectional view of the clevis of Fig. 123, showing the clevis relative to
the axle or
half shaft during operation of the vehicle at ride height;
[000139] Fig. 125 is a front view of the lower suspension arm of Fig. 116
and a
cross-sectional view of the clevis of Fig. 123, showing the clevis relative to
an axle or
half shaft during operation of the vehicle at full rebound of the suspension
assembly;
and
[000140] Fig. 126 is a perspective view of the upper suspension arm of the
suspension assembly of Fig. 12.
DETAILED DESCRIPTION OF THE DRAWINGS
[000141] With reference first to FIGS. 1-7, the vehicle of the present
invention will
be described. As shown, the vehicle is generally depicted as reference number
2 which
includes front wheels 4 and rear wheels 6. Front wheels 4 are comprised of
rims 8 and
tires 10, whereas wheels 6 are comprised of rims 14 and tires 16. Wheels 4 and
6
support a vehicle frame which is shown generally at 20 (FIG. 3) and which
supports a
seating area 22 comprised of a driver's seat 24 and a passenger seat 26. A cab
frame
is shown at 28 and generally extends over the seating area 22 to protect the
passengers from such objects as tree branches, etc. A passenger grab bar 32 is
provided for the passenger in seat 26. As best shown in FIG. 2, vehicle 2
further
includes a steering assembly at 34 for steering front wheels 4 whereby the
steering
assembly 34 includes a steering wheel 36 which could be both tiltable and
longitudinally
11
Date Recue/Date Received 2022-11-03
movable as described in U.S. Provisional Patent Application Serial Number
62/615,684
filed January 10, 2018, the subject matter of which is disclosed herein in its
entirety.
[000142] Vehicle 2 further includes a front suspension at 40, which in the
present
disclosure is a double A-arm suspension and further includes a rear suspension
42,
which as shown in the present disclosure is a trailing arm-type suspension. As
shown
best in FIGS. 2-4 (see also FIG. 22), powertrain is comprised of engine 50
(FIG. 3), a
continuously variable transmission (CVT) 52 (FIG. 3) and a shiftable
transmission 56
(FIG. 3) which is operated by a shifter assembly 60 (FIG. 5). In a preferred
version of
the present invention, the vehicle is a four-wheel drive vehicle including a
front final
drive 70 (FIG. 2) having front stub shafts 72 coupled to the front final drive
70 for driving
the front wheels 4. A rear final drive 76 (FIGS. 2, 7) is provided to drive
half shafts 78
which drives rear wheels 6. As shown vehicle 2 may also include an outer body
80
including a hood 82, side panels 84, doors 86, a utility bed 88 and rear
panels 90. The
vehicle described herein may be further configured as shown in US Patent
8,827,028
and/or US Patent application serial number 62/615,684, the subject matter of
which is
incorporated herein by reference.
[000143] With reference now to FIGS. 8-9, frame 20 will be described in
greater
detail. With reference first to FIG. 8, frame 20 is comprised of outer frame
tubes 100
and inner frame tubes 102. Outer tubes 100 include a longitudinally extending
portion
104 and vertically extending portions 106. Frame tubes 102 include
longitudinally
extending portions 108 and vertically upstanding frame tubes 110. Outer frame
tubes
112 extend forwardly and generally parallel with frame tubes 104 and couple to
upright
frame tubes 114. Frame tubes 114 support a U-shaped frame tube 116 having
couplers
118 to which cab frame 28 is attached. U-shaped tube 116 is supported by a
front
frame portion 120 comprised of a fixed front frame portion 122 and a removable
front
frame portion 124. Fixed front frame portion 122 is comprised of three sets of
upwardly
extending frame tubes, namely frame tubes 126, frame tubes 128 and frame tubes
130.
Fixed frame portion also includes transverse frame members 132 and 134 (FIG.
9).
Finally, fixed front frame portion 122 is comprised of longitudinal tube
portions 140.
12
Date Regue/Date Received 2022-11-03
[000144] With reference still to FIG. 8, a seating support is generally
shown at 150
including transverse frame tubes 152 and 154 and a longitudinal frame tube
pair 156
which support the seat 24 and a frame rail 158 to support seat 26. With
reference now
to FIG. 9, a rear of the frame 20 will be described.
[000145] With reference to FIG. 9, a powertrain support area 170 is
provided
including rearwardly extending frame tubes 172 and upwardly extending frame
tubes
174. Frame tubes 174 extend upwardly and include forwardly projecting tube
portions
174a and vertically extending portions 174b.
[000146] With reference now to FIG. 9, a cab frame support area 180 is
provided
having a transverse tube at 182, which couples to forwardly projecting tube
portions
174a of frame tubes 174. Transverse tube 182 is also coupled to frame tubes
106, 184.
Taper joint brackets 186 couple to frame tube 182 as more described herein.
Frame
tubes 190 extends upwardly from tubes 174a and include brackets 196, to which
a rear
portion of cab frame 28 is coupled, as further described herein.
[000147] With reference now to FIGS. 8 and 9, a utility bed support area
200 will be
described in greater detail. Support area 200 includes transverse tube 202
extending
between tubes 106 and supported by upright frame tubes 110. A rear transverse
tube
206 extends transversely of and is coupled to frame tubes 174. Support area
200
further includes longitudinally extending tubes 208 which couple at the rear
to tube 206
and to brackets 210 at the front end thereof.
[000148] With respect still to FIGS. 8 and 9, door support brackets are
provided on
both the driver and passenger side, whereby a bracket 224 and 226 extend
forwardly
from tube 106 on the driver's side and a bracket 224 and 228 extend forwardly
on the
passenger side.
[000149] Finally and with respect still to FIGS. 8 and 9, engine mount
brackets will
be described. As shown in FIG. 8, a left hand side mount assembly is shown at
240
and a right hand side mount assembly is shown at 242 in FIG. 9. Left and right
hand
side brackets are also shown in FIG. 9 at 244 and 246.
13
Date Recue/Date Received 2022-11-03
[000150] With reference now to FIGS. 10-15, front suspension will be
described in
greater detail. As shown in FIG. 10, frame 20 includes upper couplings 260,
262 and
lower couplings 264 and 266. Rear couplings 268 and 270 (FIG. 11) are also
provided
for the left-hand side front suspension 40 and mirror image couplings are
provided for
the right-hand side suspension 40. Suspension 40 includes an upper A-arm 280,
lower
A-arm 282 and a linear force element (LFE) 284 which is shown as a spring over
shock.
Front final drive 70 is shown positioned intermediate the front couplings 260-
266 where
half shafts 290 extend from the front final drive 70 to drive the wheel hub
292. Shock
absorber 284 is coupled to the frame at an upper bracket 296 and is coupled to
the
lower A-arm 282 by way of a clevis 298 which flanks the half shaft 290 as
described in
greater detail herein.
[000151] Front suspension 40 further comprises a stabilizer or torsion bar
300
coupled to frame tubes 128 and coupled to lower A-arms 282 as further
described
herein. As shown in FIGS. 12 and 13, torsion bar 300 includes a transverse rod
302
coupled to link arms 304 which in turn are coupled to rods 306. Rods 306 are
coupled
to brackets 308 positioned on the lower A-arms 282. As shown in FIGS. 14 and
15,
bracket 282 is comprised of plate portions 310, 312 having apertures 314, 316
therethrough to receive fasteners 320 therethrough (FIG. 12). As shown best in
FIG.
15, lower A-arm 282 includes a shock mount 330 having an aperture at 332. A
sleeve
334 is received into aperture 332 from one side thereof and a bearing 336 is
received
on the opposite side thereof and held in place with aperture 332 by way of
snap ring
338. A second sleeve 340 is positioned within aperture 332 whereupon fastener
342
may be received through sleeves 334, bearing 336 and sleeve 340 whereupon a
fastener 344 couples to fastener 342 to retain clevis 298. As shown best in
FIG. 15,
clevis 298 includes clevis legs 350 having apertures at 352 to receive
fastener 342
therethrough. The legs 350 of the clevis 298 are elongated in the vertical
direction to
allow the free movement of the half shafts 290 within the clevis 298 during
the operating
movement of the suspension. An axis 354 that runs down the axial center of the
shock
member intersects the half shaft 290.
14
Date Recue/Date Received 2022-11-03
[000152] With reference now to FIGS. 12-15, each of the control arms 280,
282 are
coupled to the frame by way of couplers 370, 372, 374, 376 and outer couplers
380,
382, 384 and 386. It should be appreciated that A-arms 280 and 282 are coupled
to the
frame by way of couplings 260-270 on the frame as described above and as shown
in
FIGS. 10-11. Outer ends of A-arms 280, 282 retain a steering spindle 390 by
way of
upper and lower ball joints 392, 394. As shown best in FIG. 13, steering
spindle 390
includes a steering link 398 to which steering arm 400 is attached by ball
joint 402.
Steering arms 400 are coupled at their inner ends to steering motor 410 having
an input
at 412 which couples through to steering system 34 so as to turn the left and
right front
wheels 4 through steering rack 414. Steering spindles 390 rotate about an axis
through
ball joints 392, 394 and at the same time retain wheel hub 292 and front
braking system
420 thereto, as described in greater detail herein.
[000153] With reference now to FIG. 16, front braking system 420 will be
described
in greater detail. As shown, braking system 420 is coupled to the steering
spindle 390
and comprises brake caliper 422, disc pads 424 and brake disc 426. As shown,
hub
292 includes an inner hub portion 292a and an outer hub portion 292b. Inner
hub
portion 292a is directly coupled to half shaft 290 so as to be driven, and hub
portion
292a includes a plurality of fasteners 428. Hub portion 292b includes a
plurality of
apertures at 430 which receive fasteners 432 therethrough and disc 426
includes
apertures 436. Hub portion 292b includes a plurality of apertures 440 which
align with
fasteners 428 so that hub portion 292b and disc 426 couple directly to the hub
portion
292a. Caliper 422 and disc pads 424 couple to a brake mount at 442 such that
disc
pads 424 are held on opposite sides of the brake disc 426. Alternatively, the
brake disc
could be shown as a single component, comprising the disk 426, hub portion
292b and
fasteners 432. Also, fasteners 432 may be rivets such as buck rivets.
[000154] With reference now to FIGS. 17-19, the removable front frame
portion 124
will be described in greater detail. As shown in FIGS. 17 and 18, the
removable front
frame portion 124 is coupled to the frame just adjacent to the suspension
couplings 260,
262, 264 and 266. Removable front frame portion 124 includes a plate section
450 to
which a bracket 452 is mounted which can provide a location for a winch mount.
A tow
Date Recue/Date Received 2022-11-03
bar 454 is mounted to the bracket 452 and a hook 456 is mounted at a lower
portion of
plate portion 450. Plate portion 450 includes four mounting holes at 458 which
provide
access to fasteners 460. Each of the apertures 458 further includes a locator
aperture
464 as further described herein.
[000155] As shown, fixed frame portion 122 includes an upper frame tube
portion
470 which is substantially parallel to lower frame tube 102 where each of the
upper
frame tubes 470 and lower frame tubes 102 include inserts 480, 482, 484 and
486. As
shown, each of the couplings 480-486 perform two functions, first to define a
portion of
the suspension couplings 260-266 as well as provide a mounting location for
the
removable frame portion 124. More particularly, insert 480 includes a
cylindrical portion
480a to which a bracket arm 480b is mounted having an aperture which defines a
mounting location for upper A-arm 280. At the same time, insert 480 includes a
raised
land 480c, a tear-drop configuration and having a threaded aperture at 480d
and a
locating lug at 480e. In a like manner, insert 482 includes a cylindrical
portion 482a,
plate 482b, raised land 482c, threaded aperture 482d and locating lug 482e.
[000156] As shown in FIG. 19, insert 484 includes a cylindrical portion
484a, plate
portion 484b, raised land 484c, threaded aperture 484d and locating lug 484e.
In a like
manner, insert 486 includes a cylindrical portion 486a, plate portion 486b,
raised land
486c, threaded aperture 486d and locating lug 486e. It should be recognized
that each
of the cylindrical portions 480a, 482a, 484a and 486a include a reduced
diameter
portion extending rearwardly therefrom which is receivable into respective
frame tubes
102 or 470 whereby the inserts 480-486 may held in place by way of industrial
adhesives or other such bonding as welding.
[000157] It should be noted from FIGS. 18 and 19, that the lands 480c-486c
provide
the interface for coupling the removable frame portion 124 to the fixed frame
portion
122. Namely, each of the apertures 458 and the movable frame portion 120 align
with
associated threaded portions 480d-486d and each of the alignment apertures 464
aligns with corresponding locating lugs 480e-486e. Thus, once aligned,
fasteners 460
are receivable through corresponding apertures 458 and into their
corresponding
threaded apertures 480d-486d. Thus to remove the front final drive 76, the
front
16
Date Recue/Date Received 2022-11-03
removable frame portion 124 is simply removed by uncoupling the fasteners 460
whereby the removable front frame portion 124 moves to the location shown in
FIG. 18,
and whereby front final drive portion 76 may be removed by uncoupling
fasteners 490
and 492 (FIG. 19).
[000158] It should be noted from FIG. 19 that the removal of the removable
frame
portion 124 and the front final drive 76 does not require the removal of the
front
suspensions 40 as the couplings 260-266 remain fixed to the fixed frame
portion 124. It
should also be noted that the front final drive 76 includes mounting inserts
496 which
couple with the fasteners 490 in a manner substantially as shown in US Patent
Application 15/389,147, the subject matter of which is incorporated herein by
reference.
[000159] In addition, the upper couplings 260, 262 serve two functions.
First, each
of the couplings 260, 262 provide the mounting structure for the front
suspension as
previously described but also include sidewalls 260a, 262a (FIG. 19) which
include the
apertures for receiving fasteners 490.
[000160] With reference now to FIGS. 20-22, rear suspension 42 will be
described
in greater detail. As shown best in FIG. 20, rear suspension 42 is shown from
an
underside thereof in association with the engine 50, CVT 52 and shiftable
transmission
56. As shown, CVT 52 is positioned forward in the support area 200 and
occupies a
space normally taken up by a torsion bar. Rear suspension 42 includes a pair
of trailing
arms 500 coupled at a front end thereof to the frame (FIG. 3) whereby the
trailing arms
rotate about axis 502 (FIG. 3), radius arms 506 are coupled at an inner end
508 to
frame 20 and at outer ends to the trailing arms 500.
[000161] With reference now to FIGS. 21 and 22, the torsion bar assembly
will be
described in greater detail. As shown, an 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 (FIG. 1). As shown, torsion bar assembly 510
couples
to the same bracket 210 that mounts the frame tubes 208 (FIG. 9), which
supports the
utility bed 88 (FIG. 2). Bracket 210 includes a bracket portion 210a for
mounting tubes
208 and a bracket portion 210b which faces rearwardly and downwardly for
mounting
17
Date Recue/Date Received 2022-11-03
the torsion bar assembly 510. Torsion bar assembly 510 includes a transverse
bar
portion 520 to which link arms 522 are fixedly mounted. Link arms 522 couple
with link
rods 524 which in turn couple to brackets 512. Torsion bar assembly 510 may be
further configured as shown in US Patent 8,827,019, the subject matter of
which is
incorporated herein by reference.
[000162] With reference now to FIGS. 21 and 22, the torsion bar assembly
510
includes bearings 530 having bearing halves 532 and a bearing collar 534.
Bearing
halves 532 are split to receive a reduced diameter section 540 in a rotatable
manner
and are received within each of the collars 534. Each collar 534 includes an
aperture at
544 which receives fasteners 546 thereth rough. Fasteners 546 extend through
apertures 548 of bracket portion 210b to couple the transverse portion 520 to
the frame
tube 210. Link arms 522 have a split opening at 550 which couples to ends 552
of
transverse portion 520. Split portions 550 include an aperture at 556 which
receives a
fastener 558 so as to clamp the split opening 550 to the portions 552. Link
arms 522
include a coupler 560 at the opposite end which corresponds with a coupling
562 of link
rods 524. Fasteners 564 are receivable through the couplers 560, 562 and is
retained
by a counter fastener 566. Lower ends of link rods 524 also includes a lower
coupler at
568 which receives a fastener 570 therethrough to couple the link arms 524 to
the
bracket 512 with a counter fastener 572.
[000163] With reference again to FIG. 20, it should be noted that the
suspension,
namely the radius rods 506, are centered about a longitudinal center line 580
of the
vehicle whereas a center line of the engine is off-set from the longitudinal
center line of
the vehicle at a center line 582. Due to the off-set of the engine 50, the
drive to the front
final drive 70 and rear final drive 76 is slightly angled. More particularly,
as shown in
FIG. 20, a rear prop shaft 586 extends at a slightly skewed angle 588 whereas
front
prop shaft 590 extends at a slightly skewed angle 592. With reference again to
FIG. 11,
front prop shaft 590 includes a coupling at 594, which may be in the form of a
universal
joint. Universal joint includes a front coupling at 596 which is directed
upwardly to the
front final drive 70. Steering gear 414 is positioned as low as possible in
the vehicle,
18
Date Recue/Date Received 2022-11-03
and is positioned in the area defined by the inclusive angle between the front
prop shaft
590 and the front coupling 596. This optimizes bump steer.
[000164] With reference now to FIGS. 23-28, a front scavenge pump for
engine 50
will be described in greater detail. As shown in FIG. 23, engine 50 drives CVT
52 which
in turn drives shiftable transmission 56. Shiftable transmission 56 is coupled
to prop
shafts 586 and 590 to drive rear final drive 76 and front final drive 70
respectively. It
should be appreciated that engine 50 is substantially as shown in US Patent
Applications 15/595,224 and 15/595,209, the subject matter of which is
incorporated
herein by reference.
[000165] As shown in FIG. 24, engine 50 includes an engine block 600, valve
cover
602, oil pan 604, oil filtration system 606 and air intake system 608. A
timing chain
cover 610 encloses the cam chain of the engine and also encloses an auxiliary
scavenge pump 612 as shown in FIG. 25. As shown in FIGS. 25 and 26, pump 612
includes an integrated pump housing 614 within the oil pan 604, including an
input area
620 and a discharge area 622. Housing portion 614 includes a circular opening
at 624
to receive outer rotor 626 and an inner rotor 628 of the scavenge oil pump. A
drive
coupler 630 is provided which couples to the main oil pump 652 at one end by
way of a
rectangular drive 632 and couples to drive gear 634 at the opposite end by way
of a
truncated circular portion 636 which corresponds with a like opening at 638 of
gear 634.
Pin 639 is positioned in aperture 630a and is received in slot 628a to drive
gerotor 628.
[000166] A cover 640 is provided having an opening at 642 which receives a
syphon screen at 644 which corresponds with opening at 620. It should be
appreciated
from the previous description of the powertrain that the cam chain oil pump
612 is
positioned longitudinally at a rear of the vehicle, such that in extreme
inclines of the
vehicle, oil floods to the cam chain area 646 which takes oil away from the
main oil
sump 648 (FIG. 25). Thus as shown in FIG. 27, the drive chain couples to gear
634,
drives gerotor 628 by way of pin 639 and drives pump shaft 650 of main oil
pump 652
by way of rectangular end portion 632. As shown in FIG. 28, oil moves in a
direction of
arrows into the inlet 644 whereupon gerotor 628 moves the oil in the direction
of arrows
19
Date Regue/Date Received 2022-11-03
660 and upward in the direction of arrows 662 and out of the cam chain arear
646 and
returning to the main sump area 648.
[000167] With reference now to FIGS. 29-33, the mounting of engine 50
within
frame 20 will be described in greater detail. As shown first in FIGS. 29-31,
left-hand
side mount assembly 240 is shown coupled to engine 50. As shown, mount
assembly
240 includes a removable mount 670 (FIG. 31) and is defined by a channel-
shaped
member having parallel plate portions 672 defining an upper platform at 674. A
front
edge of the plate portions 672 includes apertures 676 and a rear edge defines
apertures
678. Brackets 680 and 682 define apertures 684 and 686 respectively which
align with
apertures 676 and 678. Fastener 688 is receivable through apertures 676 and
684
while fastener 690 is receivable through apertures 678 and apertures 686.
Counter
fasteners 692 couple with fasteners 688 and 690 to retain left-hand side mount
assembly 240 to frame 20.
[000168] As shown in FIG. 31, a mounting bracket is shown at 700 which
couples to
the backside of transmission 56 and to the left-hand side of engine 50 as
shown in
FIGS. 29 and 30. Bracket 700 is somewhat L-shaped having a transverse leg
portion at
702 and a longitudinal leg portion at 704. Leg portion 702 includes apertures
at 706
while leg portion 704 has apertures at 708. Apertures 706 align with apertures
710 at
the back side of the transmission 56 and apertures 708 align with apertures
712 (see
FIG. 23). Fasteners 714 (see FIG. 29) are receivable through apertures 708 and
into
threaded engagement with apertures 712 (see FIG. 23). Fasteners 716 are
receivable
through apertures 706 and into threaded engagement with apertures 710. An
isolation
mount 720 is provided to interface between brackets 670 and 700. Mount 720
includes
a lower mount portion 722 which receives fasteners 724 therethrough and which
are
receivable with threaded apertures 728 of bracket 670. Mount 720 further
includes an
arcuate flange 730 having apertures at 732. A complimentary arcuate flange 740
is
positioned on bracket 700 having threaded apertures at 742. Thus, fasteners
744 are
receivable through apertures 732 and into threaded engagement with apertures
742.
Date Recue/Date Received 2022-11-03
[000169] With reference still to FIG. 31, an isolation mount 750 is shown
which is
substantially similar to mount 720 having a lower mount portion at 752 and an
arcuate
flange at 754 having apertures 756. The bracket 244 includes threaded
apertures at
758 which receives fasteners 760 therethrough and through mounts 752 to retain
mount
750 to bracket 244. Transmission 56 also includes an arcuate flange at 770
(see also
FIG. 34) having threaded apertures at 772. Fasteners 774 are receivable
through
apertures 756 and into threaded engagement with apertures 772 of transmission
56.
The location of arcuate flange 770 is further seen in FIG. 23. It should be
noticed from
FIG. 30, that bracket 670 is positioned adjacent to prop shaft 586 such that
removal of
bracket 670 and isolation mount 720 provides full access to prop shaft 586 for
removal
and/or replacement.
[000170] With reference now to FIGS. 32 and 33, the right-hand side engine
mount
will be described in greater detail. As shown, right-hand side mount assembly
242 has
an upper platform 790 which receives an isolation mount 792 in a similar
fashion to
mount 720. A bracket 794 is coupled to the right-hand side of the engine by
way of
fasteners 796 into apertures 798 (see FIG. 24). Fasteners 800 couple the
isolation
mount to bracket 794. Further details of isolation mounts may be seen in US
Patent
9,873,316, the subject matter of which is incorporated herein by reference.
[000171] With reference now to FIGS. 34-38, a torque control feature of the
transmission will be described in greater detail. With reference first to FIG.
34, the
transmission 56 is shown where the transmission includes a transmission
housing at
820 having an engine interface at 822 (FIG. 35) which defines a flange for the
mounting
of engine 50. An intermediate shaft 824 is provided having an input at 826 and
an
output at 828. The gearing for transmission 56 is located within housing
portion 830
and which is driven through input shaft 832. It should be appreciated that CVT
52 (FIG.
23) couples between shafts 828 and 832 such that the engine 50 drives
intermediate
shaft 824 and shaft portion 828 drives a drive pulley within CVT 52 and a
driven pulley
of CVT 52 drives input shaft 832 of transmission 56. As shown in FIG. 34, an
output
shaft of transmission 56 is also provided at 840 which has a shaft portion 842
coupled
21
Date Recue/Date Received 2022-11-03
to the front prop shaft 590 and a rear output shaft 844 (FIG. 35) which
couples to rear
prop shaft 586 (FIG. 23).
[000172] With reference now to FIGS. 36 and 37, a slip clutch is defined
between
the shaft portions 842, 844 to limit torque through the front prop shaft 590.
As shown,
slip clutch is defined by a plurality of friction discs 850 interposed between
a plurality of
clutch discs 852. Friction discs 850 include a plurality of pads of friction
surfaces 854
such as a carbon fiber material or graphite material to cause a frictional
engagement
between the friction discs 850 and the clutch discs 852. Each of the friction
discs 850
include teeth at 858 while the clutch discs 852 include splines 860. Shaft
portion 842
includes a reduced diameter portion 868 having a splined portion at 870, an
enlarged
diameter portion at 872, a fixed pressure plate at 874, and a splined section
at 876.
Shaft portion 842 further includes a threaded shaft portion 880 and a reduced
diameter
portion 882.
[000173] Shaft portion 844 includes a splined output shaft at 890, an
enlarged
diameter portion at 892, a disc basket 894 having a plurality of teeth 896
which match
with teeth 858 of friction discs 850. Shaft portion 844 further includes a
helical gear 898
which is the input to lower shaft 840 driven through shaft 832. Slip clutch
further
includes wave springs 900, pressure nut 902, movable pressure plate 904,
timing disc
906, bearings 908, 910 and seals 912, 914.
[000174] The plurality of friction discs 850 and clutch discs 852 are
slidably
received over spline shaft portion 876 with the splines 860 of the clutch
discs aligning
with the splines of splined portion 876. This positions the plurality of
stacked discs 850,
852 positioned against an inner surface of fixed pressure plate 874, as best
shown in
FIG. 36. Movable pressure plate 904 is thereafter received also on splined
portion 876
to be positioned against the last of the friction discs 850. Wave springs 900
are
thereafter positioned over shaft portion 880 to be positioned against pressure
plate 904
and pressure nut 902 is threadably received on shaft portion 880 and torqued
down to a
preset torque where wave springs are pressing against pressure plate 904, as
shown
best in FIG. 36.
22
Date Recue/Date Received 2022-11-03
[000175] As shown in FIG. 36, an idler shaft 920 provides a helical gear
922 in
engagement with helical gear 898. Shaft 920 is drivingly coupled to input
shaft 832
such that input torque from the engine is transferred through CVT 52 to
transmission 56
and to outputs 842 and 844. When the torque at 844 reaches a preset max
torque,
however, that is the torque where the friction discs 850 and clutch discs 852
begin to
slip relative to each other, the torque through shaft 842 is limited by the
slip clutch
defined through discs 850, 852. It should be noticed that as the friction
discs 850 are
rotationally fixed relative to the shaft portion 844 and the clutch discs 852
are
rotationally fixed relative to shaft portion 842. When the torque at output
shaft 844 is
below the threshold torque, the entire shaft 840 rotates as a single piece.
However,
when the torque exceeds the predetermined maximum torque, the discs 850, 852
slip
relative to each other, allowing a different rotational speed between shaft
portion 842
and shaft portion 844. With reference again to FIG. 36, the rotational speed
of shaft
portion 842 is measured through timing gear 906, where timing gear 906
includes a
plurality of timing tines 930 and a timing sensor is positioned in aperture
932 (FIG. 37)
to count the rotations of the tines to calculate a speed of shaft portion 842.
[000176] Thus with reference to FIG. 38, a torque model can be provided
through a
plurality of sensed perimeters, calculated perimeters and output perimeters,
where the
shaft speed of the front shaft portion 842 is determined at 940, the shaft
speed of rear
shaft portion 844 is determined at block 942 and a differential between the
two shaft
portions 842, 844 is determined at block 944 so as to define a shaft speed
deferential at
948. Thus, as mentioned above, if the torque at shaft portion 844 is below the
predetermined maximum torque, the shaft speed differential at block 948 is 0.
When
the torque at shaft portion 844 exceeds the predetermined maximum torque, the
discs
850, 852 begin to slip such that a shaft speed differential is calculated, is
input to the
torque model at block 950 and the engine output torque is limited by the
engine control
unit at block 952.
[000177] With reference now to FIGS. 39-41, CVT 52 will be described in
greater
detail. As shown, CVT 52 includes an inner housing 970 (adjacent the engine 50
and
transmission 56) and an outer housing 972. CVT 52 would also include a drive
side 974
23
Date Recue/Date Received 2022-11-03
and a driven side 976, and including a drive clutch 978 and a driven clutch
980 (FIG.
41). CVT 52 has a forward intake 982, a rear intake 984 and an exhaust 986.
CVT 52
may also be configured as shown in US Patent application serial number
62/644,717,
filed March 19,2018, the subject matter of which is incorporated herein by
reference.
[000178] As the engine 50 is not coupled directly to the CVT 52, but rather
to the
engine interface 822 (FIG. 35), the intermediate shaft 824 output 828 extends
through a
shaft housing 990 (FIG. 34) which has a small profile in the radial direction.
The shaft
housing 990 also protrudes through the opening 992 as best seen in FIGS. 40
and 41,
providing a large space 994 around the inner sheave portion 996. The spacing
994
provides an air volume and allows a substantial amount of air flow around the
inner
sheave portion 996 and outer sheave portion 998 for cooling.
[000179] With reference now to Fig. 42, a coolant bottle is shown at 1000
having an
integrated switch to determine coolant level.
[000180] With reference now to FIG 43, the utility bed 88 is shown to
include
channels 1002 and drains 1004 to remove contaminants so as to not drain on hot
portions of the power train.
[000181] With reference now to FIGS. 44 and 45, fuel tank 1050 is shown
positioned beneath and rearward of passenger seat 26. As shown, fuel tank 1050
includes a longitudinally extending section at 1052 which is lower than and
under seat
26. Longitudinal section 1052 includes fuel pump 1054 which draws fuel from
the
lowest portion of the fuel tank 1050. Fuel tank 1050 also includes a
vertically extending
section at 1060 which includes the filler tube at 1062. As shown, vertically
extending
section 1060 is rearward of passenger seat 26.
[000182] With reference now to FIGS. 1-5 and 46-49, cab frame 28 will be
described in greater detail. As shown first in FIGS. 1-5, cab frame 28
generally includes
longitudinally extending frame members 1070 and 1072 which couple to couplers
1074
and 1076 at a front end thereof and to couplers (not shown) at the rear
thereof. A mid
frame portion 1080 and 1082 extends downwardly at a position adjacent to seats
24
and 26 and couple to couplers 1086. With reference now to FIGS. 46-49,
couplers
24
Date Recue/Date Received 2022-11-03
1086 will be described in greater detail. As shown in FIG. 47, coupling 1086
includes a
tapered lower portion at 1090 which extends along an axis 1092 which is common
with
the axis to coupling 186. An upper portion of coupling 1086 includes a collar
1094
which is skewed relative to axis 1092 and includes an opening at 1096 which
allows
access to an opening 1100 extending through tapered portion 1090 (see FIG.
48).
[000183] Coupling 186 includes a tapered portion 1102 conforming to the
tapered
portion 1090 and which has a lower portion 1106 having an opening at 1108. An
aperture 1110 provides access between opening 1108 and tapered portion 1100
for
receiving a fastener such as 1114. A counter fastener 1116 is positionable
through a
retaining portion 1112 in opening 1096 which retains fastener 116 and prevents
rotation
of fastener 116. Thus, coupling portion 1086 may be coupled to coupling 186 on
tube
182 by positioning tapered portion 1090 within coupling 186. This positions
the tapered
portion 1090 within the tapered portion 1102 of coupling 186 as shown best in
FIG. 48.
Fastener 1114 is thereby positioned through opening 1110 which positions the
threaded
portion within the opening 1096 of coupling 1086. Fastener 1116 may then be
threaded
onto the threads of fastener 1114 to secure the tube 1082 to tube 182.
Alternatively,
brackets 196 (FIG. 9) can also be replaced with tapered couplings 186.
Preferably,
axes 1092 of all tapered couplings 186 would be parallel.
[000184] With reference now to FIG. 50, a joint 1120 is shown which
provides a
joinder of tubes 106 and 176 to the larger tube 182. In this case, the tube
106 (referred
to as a poke yoke pass through tube) is inserted through both walls of larger
diameter
tube 182, that is, through openings 1122 and 1124. This is a very efficient
way to
transmit bending moments and load the section properly, particularly where
multiple
tubes share a common node in a space frame welded structure.
[000185] Instead of un-sharing multiple tube nodes to keep proper weld
shelf, a
poke yoke pass through tube profile may be added to the laser cut tube to
obtain proper
weld shelf, increase fatigue life, and eliminate weld fixture loading sequence
issues.
There is also a reduction in total weld length required as a small cost
benefit. The
plastics packaging required the tube to only have -270 degrees of wrap. As
also
Date Recue/Date Received 2022-11-03
shown, the partially inserted tube 176 finds a natural stop against the poked
through
tube 106.
[000186] With reference now to FIGS. 51-55, an alternate front frame will
be
described which could be used in place of the front frame as described in
FIGS. 17-19.
As shown, front frame 1320 includes a front frame portion 1322 and a removable
front
bumper portion 1324 (FIG. 52). As shown in FIG. 52, front frame 1322 is
generally
comprised of lower longitudinal tube portions 1330, upper longitudinal tube
portions
1332, front diaphragm plate 1334, and left and right-side plates 1336 and 1338
(FIG.
53), respectively.
[000187] As shown best in FIG. 53, lower longitudinal tube portions 1330
include
threaded inserts 1340 whereas upper longitudinal tube portions 1332 include
threaded
inserts 1342. Front pedestal plate 1334 is coupled to the lower longitudinal
tube
portions 1340 and upper longitudinal tube portions 1342 and includes an
opening 1350
generally conforming to allow the passage of front drive 70 therein, as will
be described
in greater detail herein. Side plate 1336 is generally coupled to the left-
hand side lower
longitudinal tube portion 1330 and upper longitudinal tube portion 1332, as
best shown
in FIG. 54. Left plate portion 1336 includes an opening at 1360 to allow
access
between front drive 70 and left front wheel. Left side plate 1336 further
includes a front
opening at 1362 and a rearward opening at 1364 which align with mounting
inserts 496
(FIG. 53) as further described herein. A front pedestal 1370 is positioned
below
aperture 1362 and a rearward pedestal 1372 is positioned below opening 1364.
Pedestal 1370 defines a mounting surface at 1374 while pedestal 1372 defines a
mounting surface at 1376.
[000188] With reference now to FIG. 55, right-hand side plate 1338 is
coupled to
lower longitudinal tube portions 1330, and upper longitudinal tube portions
1332. Plate
1338 includes an opening at 1380 and which is substantially identical to the
opening
1370, and which allows access between right front wheel and final drive 70.
Right plate
1338 also includes a forward aperture at 1382 and a rearward aperture at 1384.
Note
that apertures 1382 and 1384 align with, and may be viewed through, the left-
hand side
plate 1336 through openings 1362 and 1364, respectively, as viewed in FIG. 54.
26
Date Recue/Date Received 2022-11-03
[000189] With reference again to FIG. 53, front final drive 70 is
insertable through
opening 1350 through diaphragm plate 1334. The front final drive 70 is
inserted until
the mounting inserts 496 align with respective openings 1362 and 1364 (FIG.
54) of the
left-hand side plate 1336. Mounting anchors 1390 and 1392 are provided, which
are L-
shaped in configuration having vertical portions 1390a, 1392a, horizontal
portions
1390b and 1392b. Apertures 1390c, 1392c and 1390d and 1392d are provided for
mounting as described herein. Anchors 1390 and 1392 align with mounting
inserts 496
of front final drive 70 whereupon vertical portions 1390a and 1392a couple
through
openings 1362 and 1364 to contact mounting inserts 496. This positions the
horizontal
portions 1390b and 1392b upon pedestals 1374 and 1376, respectively. This also
aligns apertures 1390d, 1392d with apertures 1374a and 1376a, respectively.
Vertical
fasteners 1400 and 1402 are receivable through apertures 1390d and 1392d, and
apertures 1374a and 1376a to receive counter fasteners 1404 and 1406. At the
same
time, fastener 1410 is receivable through aperture 1390c, through the front
mounting
insert 496 and through aperture 1382 of right-hand side plate 1338 to receive
a counter
fastener 1414. In a like manner, fastener 1412 is receivable through aperture
1392c,
rear mounting insert 496, through aperture 1384 to receive counter fastener
1416.
[000190] In the preferred method of installation, the horizontal fasteners
1410 and
1412 are inserted first while the vertical fasteners 1400, 1402 and anchors
1390, 1392
are loosely installed. The horizontal fasteners 1410 and 1412 are torqued to
their
nominal torque rating which provides no pre-load stress to the anchors 1390
and 1392.
Rather, the anchors 1390 and 1392 remain resting upon their corresponding
surfaces
1374 and 1376. Once the horizontal fasteners 1410 and 1412 are torqued,
fasteners
1400 and 1402 may then be torqued to provide the final locating position of
the front
final drive 70.
[000191] With reference now to FIG. 52, removable bumper 1324 includes a
plate
1430 to which bumper bar 1432 is attached. Fasteners 1434 are receivable
through the
plate portion 1430 and into threaded fasteners within couplers 1342. Thus, as
should
be appreciated, to remove front final drive 70, bumper 1324 is removed and
front final
drive 70 may be pulled through opening 1350 of 1334.
27
Date Recue/Date Received 2022-11-03
[000192] Referring to Figs. 56-114, various alternative embodiments to
those
disclosed herein with respect to Figs. 1-55 and/or additional features and
systems of
vehicle 2 are disclosed, with like components have the same or similar
reference
numbers. With respect to Figs. 56-68, an alternative embodiment of frame 20
and cab
frame 28 (Figs. 1-9) are disclosed as frame 2020 and cab frame 2028. More
particularly,
as shown in Figs. 56-60, frame 2020 includes frame tubes 2102 extending
generally
longitudinally and frame tubes 2114 extending generally vertically. Frame 2020
further
includes frame members 4000 coupled to frame tubes 2114 and extending
generally
inward therefrom. Illustratively, frame 2020 includes at least two frame
members 4000
and each includes a bracket 4002 coupled thereto. In various embodiments,
bracket
4002 is integrally coupled with frame member 4000 and may be integrally formed
with
frame member 4000 (e.g., through welds, adhesive, or rivets). Bracket 4002
includes a
tie-down member 4004 which, illustratively, defines a bar or other structure
configured to
support a load coupled thereto. In this way, bracket 4002 and tie-down member
4004
define an integrated tie-down assembly supported by frame 2020 such that a
load at tie-
down member 4004 and bracket 4002 also is supported by frame 2020 and may be
distributed through at least a portion of frame 2020.
[000193] Referring still to Figs. 56-60, frame 2020 may include additional
brackets
4008 and tie-down members 4010. For example, bracket 4009 may include a tie-
down
member similar to tie-down member 4004 or, as disclosed further herein,
similar to a tie-
down member 4010. Additionally, a rear portion of frame 2020 includes frame
tubes 2172
extending generally longitudinally and frame tubes 2240 and 4006 extending
generally
vertically and coupled with and/or positioned adjacent frame tubes 2172.
Illustratively,
frame tubes 4006 are positioned longitudinally rearward of frame tubes 2240
and are
coupled directly with frame tubes 2172. In one embodiment, frame 2020 includes
at least
two frame tubes 4006 and each frame tube 4006 includes bracket 4008 integrally
coupled
thereto. Bracket 4008 also is integrally coupled with frame tube 2174, which
is positioned
above frame tubes 2240 and 4006 and extends generally longitudinally. As shown
in at
least Fig. 57, an upper portion 4012 of bracket 4008 is integrally coupled
with frame tube
2174 and a lower portion 4014 of bracket 4008 is integrally coupled with frame
tube 4006.
28
Date Regue/Date Received 2022-11-03
[000194] Bracket 4008 includes tie-down member 4010 which, illustratively,
defines
a bar or other structure configured to support a load coupled thereto. In one
embodiment,
tie-down member 4010 is coupled to lower portion 4014 of bracket 4008,
however, tie-
down member 4010 can be coupled to any portion of bracket 4008. In this way,
bracket
4008 and tie-down member 4010 define an integrated tie-down assembly supported
by
frame 2020 such that a load at tie-down member 4010 and bracket 4008 also is
supported
by frame 2020 and may be distributed through at least a portion of frame 2020.
[000195] It may be appreciated that brackets 4002, 4008 and tie-down
members
4004, 4010 may be positioned at any height along frame 2020. Additionally,
brackets
4002, 4008 and tie-down members 4004, 4010 may be positioned within a
predetermined
lateral distance of a longitudinal centerline L (Fig. 5) of vehicle 2. For
example, tie-down
members 4004, 4010 may be positioned laterally outboard of centerline L by
approximately 12-36 inches and, more particularly, may be positioned laterally
outboard
of centerline L by approximately 24 inches. Further, as shown, both the left
and right
sides of vehicle 2 include tie-down members 4004, 4010 such that there is at
least one
tie-down member 4004, 4010 on each lateral side of centerline L. Additionally,
tie-down
members 4004, 4010 may include a double-shear clevis attachment for loading
the
corresponding frame tubes and distributing the load to these sections or tubes
or frame
2020.
[000196] Referring to Figs. 61 and 62, alternative embodiment cab frame
2028
(compared to that shown in Figs. 1-9 and 46-50) is shown. Cab frame 2028
extends over
seats 24, 26 (Fig. 1) and is coupled to frame 2020. Cab frame 2028 includes
frame
members or frame portions 3070, 3072, 3080, 3082, each of which is coupled to
frame
2020 (Fig. 56) through complementary couplers. In one embodiment, cab frame
2028 is
a single weldment such that frame members 3070, 3072, 3080, 3082, and any
other frame
member of cab frame 2028 are integrally formed together (e.g., define a single
weldment).
Various frame members or portions of cab frame 2028 may include openings or
apertures
4016 configured to expose an inner volume of such frame members or portions.
Openings 4016 are illustratively shown on frame portions 3072 and 3082,
however,
openings 4016 may be positioned on frame members or portions 3070 and/or 3080.
Openings 4016 are configured as pass-through openings to allow various wires,
conduits,
29
Date Regue/Date Received 2022-11-03
lines, or other components of vehicle 2 to extend within cab frame 2028 rather
than being
exposed such that these components may extend between frame members 3072 and
frame portions 3080, 3082 without being exposed to seating area 22 (Fig. 1).
This may
protect such components from damage or wear and also may increase the
aesthetics of
vehicle 2.
[000197] Referring to Figs. 63-68, the rear portion of frame 2020 includes
alternative
embodiment utility bed support area 2200 (compared to support area 200 of at
least Figs.
8 and 9). Support area 2200 includes tubes 2206 and 2208, where tubes 2208
extend
generally longitudinally and are coupled with tube 2206, which extends
generally laterally
and perpendicularly to tubes 2208. Support area 2200 further includes braces
4017
extending between tubes 2208 and generally parallel to tube 2206.
Illustratively, braces
4017 are positioned longitudinally forward of tube 2206.
[000198] In one embodiment, tubes 2208 are removably coupled to brackets
4020
on a cross-member 4018 with fasteners 4022. Cross-member 4018 may be part of
frame
2020 and coupled to frame tubes 2240. As shown in at least Figs. 64 and 65,
cross-
member 4018 is positioned vertically lower than transverse tube 2182. Tubes
2208
extend longitudinally from cross-member 4018 and a rear end of tubes 2208 is
coupled
with tube 2206.
[000199] As shown best in Fig. 56A, brackets 4020 are coupled to cross-
member
4018 and, more particularly, brackets 4020 extend through a recess or opening
4019 of
cross-member 4018. Illustratively, opening 4019 is a pass-through opening in
which a
portion of bracket 4020 extends completely through opening 4019. In this way,
a forward
portion of bracket 4020 is positioned forward of cross-member 4018 and a
rearward
portion of bracket 4020 is positioned rearward of 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 therebetween fully 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 fully surround opening
2019. This
configuration of brackets 4020 and cross-member 4018 allows for support area
2200 to
be able to support multiple components of vehicle 2, such as coolant bottle
3000, utility
bed 2088, and portions of air intake assembly 2608 and exhaust 2986, as
disclosed
Date Recue/Date Received 2022-11-03
further herein, because the load from such components may be distributed
through other
portions of frame 2020 (e.g., cross-member 4018) and does not need to be
supported
only at brackets 4020 and tubes 2208.
[000200] Tube 2206 is removably coupled to brackets 4008 with fasteners
4024. As
shown best in Figs. 63-65, upper surfaces of tubes 2206 and 2208 and braces
4017 are
flush with each other such that tubes 2206, 2208 and braces 4017 define a
generally
planar or flat surface. In this way, support area 2200 is configured to
support at least one
component of vehicle 2 thereon and, more particularly, is configured to
support utility bed
2088 thereon.
[000201] Referring to Figs. 67 and 68, a bottom surface 4026 of utility bed
2088
includes guides 4028. Guides 4028 extend downwardly from bottom surface 4026
and
may be removably coupled to bottom surface 4026 or may be integrally formed
with
bottom surface 4026. Guides 4028 are configured to extend along a laterally
inner
surface 2209 of tubes 2208 such that guides 4028 laterally overlap a portion
of tubes
2208. In this way, when utility bed 2208 is positioned on support area 2200,
guides 4028
are positioned along and in contact with inner surface 2209 of tubes 2208 such
that utility
bed 2088 is in the correct position for centering on and securing to support
area 2200. It
may be appreciated that guides 4028 are configured to be spaced apart from
each other,
where necessary, to receive or otherwise accommodate components of support
area
2200, such as braces 4017. When correctly positioned on support area 2200,
utility bed
2088 may be fastened thereto with couplers, such as bolts, screws, ties, etc.
[000202] Referring still to Figs. 63-68, support area 2200 not only
supports utility bed
2088 but also is configured to support additional components of vehicle 2. For
example,
as shown best in Figs. 63 and 66, support area 2200 is configured to support a
portion of
air intake assembly 2608, a portion of exhaust assembly 2986, a portion of the
cooling
assembly of vehicle 2 (e.g., coolant bottle 3000), and various panels of outer
body 80
(e.g., rear fenders, rear close-off panels, rear bumper, etc.).
Illustratively, a forward
portion of support area 2200 supports and may be coupled to an airbox 4030 of
air intake
assembly 2608 such that airbox 4030 is supported on at least tubes 2208.
Additionally,
a rearward portion of support area 2200 supports and may be coupled to a
muffler or
silencer 4032 of exhaust assembly 2986. As shown in Fig. 66, brackets 4034
extend
31
Date Recue/Date Received 2022-11-03
from at least tubes 2208 and are coupled to support arms 4036 which are
attached to
muffler 4032.
[000203] Referring to Figs. 69 and 70, front suspension 2040 is shown. As
noted
herein with respect to Figs. 12 and 13, front suspension 2040 includes upper
alignment
arm or A-arm 2280, lower alignment arm or A-arm 2282, and LFE or shock
absorber
2284. LFE 2284 is operably coupled to lower A-arm 2282 through a clevis 2298.
More
particularly, clevis 2298 has a generally U-shaped body extending between an
upper end
4040 and a lower end 4042. Lower end 4042 is removably coupled to lower A-arm
2282
with a fastener 4044, such as a bolt. Clevis 2298 is configured to receive or
straddle a
portion of half shaft 2290 such that clevis 2298 and LFE 2284 do not interfere
with the
desired location or rotational movement of half shaft 2290. In this way, half
shaft 2290 is
positioned vertically intermediate upper and lower ends 4040, 4042 of clevis
2298.
[000204] As shown best in Fig. 70, upper end 4040 of clevis 2298 is coupled
to a
lower portion of LFE 2284. More particularly, upper end 4040 of clevis 2298
includes an
aperture 4049 configured to receive a threaded end 4048 of LFE 2284. Threaded
end
4048 is aligned with a piston assembly 4046 of LFE 2284 and, illustratively,
may be
colinear with a rod portion of piston assembly 4046. Additionally, the lower
portion of LFE
2284 includes a spring retainer 4047 which is rotationally oriented or clocked
through an
interface to clevis 2298. Illustratively, clevis 2298 includes a tab 2299
which fits within a
slot 4045 on spring retainer 4047 to allow rod 4046 to pass through when
installing spring
retainer 4047 on LFE 2284.
[000205] By using clevis 2298, front suspension 2040 and the steering
assembly of
vehicle 2 may be compactly packaged and a longer LFE 2284 may be used without
compromising the weight of vehicle 2.
[000206] Referring to Figs. 69-73, front braking system 2420 is shown
positioned
adjacent front wheel hub 2292. As shown, braking system 2420 is coupled to
steering
spindle 2390 and comprises brake caliper 2422, disc pads 2424, and brake disc
2426.
Hub 2292 includes a plurality of apertures 2430, 2440 which receive fasteners
(not
shown) therethrough and disc 2426 includes apertures 2436 such that hub 2292
and disc
2426 may be coupled together and coupled to a portion of spindle 2390. Caliper
2422
32
Date Recue/Date Received 2022-11-03
may include castellated pistons which to reduce weight, as disclosed further
herein, and
may facilitate thermal management of front braking system 2420.
[000207] Caliper 2422 and disc pads 2424 couple to a brake mount at 2442
(Fig. 72)
such that disc pads 2424 are held on opposite sides of brake disc 2426.
Alternatively,
brake disc 2426 could be shown as a single component, comprising disc 426, at
least a
portion of hub 2292, and fasteners (not shown).
[000208] The configuration of front braking system 2420 allows for
integration of
caliper 2422 with spindle 2390, thereby reducing weight and size at ground-
engaging
members 4 and minimizing the need for additional protective measures for brake
caliper
2422. More particularly, braking system 2420 and the connection of steering
arms 400
(Figs. 12-15) to spindle 2390 at ball joint connection 4041 (Fig. 71) are
positioned
longitudinally rearward of the wheel's rotational axis R (Fig. 69). As such,
brake caliper
2422 may require less protection from debris and mud accumulation than in
other
positions and the weight and size of ground-engaging member 4 and/or front
braking
system 2420 may be reduced.
[000209] Referring to Fig. 74, a rear braking system 4050 is shown and may
be
similar to front braking system 2420. Rear braking system 4050 includes brake
caliper
4052, disc pads (not shown), and brake disc 4054. Caliper 4052 and the disc
pads may
be coupled to a brake mount at 4054 such that the disc pads are held on
opposite sides
of brake disc 4054.
[000210] Referring now to Figs. 74-78, rear suspension 2042 is shown. Rear
suspension 2042 includes trailing arms 2500, upper radius arms or rods 2506,
lower
radius arms or rods 4062, LFEs or shock absorbers 4060, and toe links or arms
4064.
As shown best in Fig. 74, LFE 4060 is coupled to an upper surface of trailing
arm 2500
through a shock mount 4066. Shock mount 4066 is positioned longitudinally
along the
length of trailing arm 2500 and is positioned longitudinally forward of a rear
end portion
or knuckle carrier 4058 of trailing arm 2500. Knuckle carrier 4058 may be
stamped to
reduce the weight of rear suspension 2042. Knuckle carrier 4058 may be cast to
reduce
the complexity of rear suspension 2042. The upper surface of trailing arm 2500
also may
include a mount 4067 configured to receive a portion of torsion bar assembly
510 (Fig.
21).
33
Date Recue/Date Received 2022-11-03
[000211] Knuckle carrier 4058 of trailing arm 2500 includes an opening 4068
configured to receive rear half shaft 2078. Knuckle carrier 4058 further
includes a
rearward surface 4070 configured to support outer ends of upper and lower
radius rods
2506, 4062. More particularly, rearward surface 4070 includes a mounting
member 4072
configured to support radius rods 2506, 4062. In one embodiment, mounting
member
4072 is integrally formed with knuckle carrier 4058 of trailing arm 2500,
while in other
embodiments, mounting member 4072 is removably coupled to knuckle carrier
4058. The
outer ends of radius rods 2506, 4062 are positioned longitudinally
intermediate mounting
member 4072 and knuckle carrier 4058 such that mounting member 4072 defines
the
rearwardmost surface of rear suspension 2042. Illustratively, radius rods
2506, 4062 are
positioned longitudinally rearward of rear half shaft 2078.
[000212] Referring still to Figs. 74-78, trailing arm 2500 includes an
opening 4074
which extends between an inner portion 4076 and an outer portion 4078 of
trailing arm
2500. Inner and outer portions 4076, 4078 may define a clamshell design and
are
stamped components which join together to define trailing arm 2500. Portions
4076, 4078
may be symmetrical on the right and left sides of rear suspension 2042 which
minimizes
tooling during the manufacturing process, thereby reducing cost. Additionally,
because
portions 4076, 4078 are stamped, rear suspension 2042 may be made lighter.
[000213] Trailing arm 2500 extends between a forward portion 4090 and
knuckle
carrier 4058. Forward portion 4090 includes a coupler 4092 configured to
operably
coupled to frame 2020 and allow for generally vertical movement of trailing
arm 2500
during operation of vehicle 2. Knuckle carrier 4058 is coupled to a rearward
portion 4091
of trailing arm 2500 which, illustratively, generally defines a "V" shape at
4093. Rearward
portion 4091 may be fixed to knuckle carrier 4058 through welding. The
configuration of
trailing arm 2500 and the connection to knuckle carrier 4058 may distribute
loads at
trailing arm 3500 more efficiently and increase the weld content at the
interface between
rearward portion 4091 and knuckle carrier 4058.
[000214] Opening 4074 extends completely through trailing arm 2500 and is
configured to receive a portion of toe link 4064. More particularly, toe link
4064 extends
generally longitudinally between a forward end 4080 and a rearward end 4082.
Forward
end 4080 includes a coupler 4084 configured to operably couple with a portion
of frame
34
Date Regue/Date Received 2022-11-03
2020. Rearward end 4082 includes a coupler 4086 configured to be operably
coupled to
a hub assembly 4088 of rear ground-engaging member 6 (Fig. 1). Coupler 4086
may
define a joint loaded in double shear. A corresponding bearing may be loaded
radially
and, as such, the risk of coupler 4086 and the bearing pulling apart if
coupler 4086
becomes worn is minimized.
[000215] Coupler 4086 may be positioned within an opening 4087 of knuckle
carrier
4058 of trailing arm 2500. As shown best in Figs. 76A-76C, coupler 4086 may
include a
bolt 4400, an eccentric washer 4402, and a nut 4404 which, collectively,
provide the ability
to adjust alignment of toe link 4064 by rotating bolt 4400 before tightening
nut 4404. Bolt
4400 may be mechanically coupled to washer 4402, through knurling, a D-
profile, or other
shape. The washer profile is eccentric to the bolt axis and knuckle carrier
4058 may have
locating tabs that washer 4402 contacts. In this way, as bolt 4400 is turned,
washer 4402
moves the bolt axis fore and aft in the opening. Once bolt 4400 is rotated to
provide the
desired alignment of toe link 4064, the bolt head is fixed in position and nut
4404 is
tightened to the desired torque.
[000216] As shown best in Fig. 75, toe link 4064 extends diagonally through
opening
4074 such that forward end 4080 is positioned inwardly of outer portion 4078
of trailing
arm 2500 while rearward end 4082 is positioned outwardly of inner portion 4076
of trailing
arm 2500. In this way, the configuration of rear suspension 2042 may be
compact so as
to not interfere with other components or systems of vehicle 2, such as the
powertrain or
driveline, but opening 4074 provides sufficient space for toe link 4064 to
move with or
relative to trailing arm 2500 when needed.
[000217] Additional details of rear suspension 2042 may be disclosed in
U.S. Patent
Application Serial No. 16/266,797, filed December 20, 2018, and entitled "REAR
SUSPENSION ASSEMBLY FOR A VEHICLE" (Attorney Docket No. PLR-15-28340.05P-
US), the complete disclosure of which is expressly incorporated by reference
herein.
[000218] Referring to Figs. 79-93, portions of the powertrain of vehicle 2
are
disclosed. As disclosed herein, the powertrain of vehicle 2 includes at least
engine 50
and CVT 52 (Figs. 23 and 24). At the interface between engine 50 and CVT 52
may be
an arc spring assembly 4100 (also shown in Fig. 41). More particularly, arc
spring
assembly 4100 may be positioned intermediate a crankcase of engine 50 and
drive clutch
Date Regue/Date Received 2022-11-03
978 (Figs. 39-41) of CVT 52 and, in one embodiment, directly coupled to a
crankshaft
4102 of engine 50 and drive clutch 978 of CVT 52. Illustratively, as shown
best in Fig.
81, arc spring assembly 4100 is directly coupled to an input end 4104 of
crankshaft 4102.
By positioning arc spring assembly 4100 at input end 4104 of crankshaft 4102
and
adjacent drive clutch 978 of CVT 52, vibrations at engine 50 are absorbed and
do not
transfer to CVT 52. In other words, arc spring assembly 4100 reduces or
dampens the
applied shaking forces from crankshaft 4102 during the engine firing events,
thereby
increasing the life of CVT 52 by reducing the torsional pulsation to decrease
the
temperature of the CVT belt.
[000219] Arc spring assembly 4100 includes an arc spring damper assembly
4110, a
ring gear 4112 positioned around a flex plate 4111, and a hub 4114. Hub 4114
is coupled
to input end 4104 of crankshaft 4102. Hub 4114 includes apertures 4120, at
least some
of which align with apertures 4122 on input end 4104 to receive fasteners 4118
(e.g.,
bolts, rivets, etc.). Flex plate 4111 and ring gear 4112 are positioned
adjacent hub 4114
such that hub 4114 is positioned intermediate flex plate 4111 and input end
4104 of
crankshaft 4102. Ring gear 4112 has a larger diameter than hub 4114 and
includes a
plurality of teeth 4124 along an outer circumference thereof. Flex plate 4111
includes a
plurality of locating members (e.g., dowels or pins) 4113 configured to
properly locate
CVT 52 relative to engine 50 (e.g., may be used for proper positioning on the
flywheel of
engine 50). Additionally, flex plate 4111 includes a plurality of mounting
members 4115
(e.g., studs) configured to couple to arc spring damper assembly 4110. Flex
plate 4111
also includes a plurality of apertures 4126 configured to align with apertures
4120 and
4122 to receive fasteners 4118 for coupling flex plate 4111 and hub 4114 to
input end
4104 of crankshaft 4102.
[000220] A mounting plate 4116 may positioned on the opposite side of flex
plate
4111 relative to hub 4114 such that flex plate 4111 is positioned intermediate
mounting
plate 4116 and hub 4114. Mounting plate 4116 includes a plurality of apertures
4128
configured to align with apertures 4120, 4122, 4126 to receive fasteners 4118
for coupling
mounting plate 4116 with flex plate 4111, hub 4114, and input end 4104.
[000221] Arc spring damper assembly 4110 is positioned adjacent mounting
plate
4116 such that mounting plate 4116 is intermediate flex plate 4111 and arc
spring damper
36
Date Recue/Date Received 2022-11-03
assembly 4110. Arc spring damper assembly 4110 includes a spring body cover
4130,
a drive plate 4132, and a threaded aperture 4134. Threaded aperture 4134 is
configured
to receive a portion of shaft 824 and/or shaft 828 (Fig. 41) such that
crankshaft 4102
drives drive clutch 978 of CVT 52 (Fig. 41) through arc spring assembly 4100.
Threaded
aperture 4134 may be centrally positioned on spring body cover 4130. In this
way, arc
spring assembly 4100 is directly coupled to crankshaft 4102 and drive clutch
978.
Through this direct connection between crankshaft 4102 and drive clutch 978,
arc spring
assembly 4100 becomes the decoupling device between drive clutch 978 and
engine 50.
The use of arc spring assembly 4100 reduces side load on crankshaft 4102 to
increase
the life of engine 50 and the life of the belt of CVT 52, as further disclosed
herein.
[000222] Drive plate 4132 includes couplers 4136 which are configured to
receive
mounting members 4115 on flex plate 4111 for coupling together arc spring
damper
assembly 4110 and flex plate 4111.
[000223] As shown best in Figs. 83 and 84, spring body cover 4130 includes
at least
one spring 4138 extending at least partially around threaded aperture 4134 and
having a
coiled shape. Springs 4138 may be retained by a spring retainer 4139. Springs
4138 are
configured to receive and absorb vibrational forces from engine 50 to minimize
transfer
of such vibrational forces to CVT 52, as disclosed further herein. In this
way, arc spring
assembly 4100 is configured to increase the life of CVT 52 by minimizing wear
thereto.
[000224] More particularly, the torque path through arc spring damper
assembly 4110
is shown as the arrows in Fig. 84. Torque initially is transmitted through
drive plate 4132
and then transmitted through spring body cover 4130. Torque is transmitted
through
spring body cover 4130 and then transmits along fasteners 4118 between spring
body
cover 4130 and spring retainer 4139. Torque then transmits through spring
retainer 4139
before transmitting through springs 4138 and ultimately transmitting through a
flange
4131 and a hub 4137 generally surrounding threaded opening 4134. Springs 4138
provide the damper capacity stop when the inner diameter coils go solid. It
may be
appreciated that if the torque increases to an amount greater than the spring
capacity,
the torque still follows the same torque path disclosed in Fig. 84.
[000225] Referring to Figs. 85-88B, a further portion of the powertrain of
vehicle 2 is
disclosed. Illustratively, and similar to that disclosed in Fig. 53 with
respect to supporting
37
Date Recue/Date Received 2022-11-03
front drive 70 on frame 20 or 2020, lower longitudinal tube portions 1330
include threaded
inserts 1340 whereas upper longitudinal tube portions 1332 include threaded
inserts
1342. Front pedestal plate 1334 is coupled to the lower longitudinal tube
portions 1340
and upper longitudinal tube portions 1342 and includes an opening 1350
generally
conforming to allow the passage of front drive 70 therein, as described in
greater detail
herein. Side plate 1336 is generally coupled to the left-hand side lower
longitudinal tube
portion 1330 and upper longitudinal tube portion 1332. Left plate portion 1336
includes
an opening at 1360 to allow access between front drive 70 and left front
wheel. Left side
plate 1336 further includes a front opening at 1362 and a rearward opening at
1364 which
align with mounting inserts 496, as further described herein. A front pedestal
1370 is
positioned below aperture 1362 and a rearward pedestal 1372 is positioned
below
opening 1364. Pedestal 1370 defines a mounting surface at 1374 while pedestal
1372
defines a mounting surface at 1376.
[000226] Fasteners 1410, 1412 are installed through plate portions 1336 and
through
front drive 70 and are tightened without any preload loss at the joint. The
plate portions
1336 are castings which have smooth radii and offer complete contact. More
particularly,
the boss on plate portions 1336 has proper contact with an isolator to prevent
the isolator
from tearing and cutting. Once fasteners 1410, 1412, which are horizontal
fasteners, are
tightened, vertical fasteners 1400, 1402 are tightened. If the order of
tightening the
horizontal and vertical fasteners is reversed, then plate portions 1336 will
be pre-stressed
in bending and may fatigue early. In this way, front drive 70 utilizes a slip
joint to remove
the bolt preload and facilitate installation.
[000227] Referring to Figs. 87A and 87B, and similar to front drive 70,
rear drive 2076
may be similarly mounted to frame 2020. More particularly, rear drive 2076 may
include
bosses 4410 extending generally laterally and configured to receive removable
fasteners
4412 therethrough. Fasteners 4412 also extend through openings in a mounting
bracket
4414 and, as such, couple together mounting bracket 4414 and the housing of
rear drive
2076 with couplers 4416. It may be appreciated that brackets 4414 are
removable from
frame 2020 to facilitate service and assembly of rear drive 2076.
[000228] Brackets 4414 are coupled to a brace 4420 extending between and
coupled
to frame tubes 2174. More particularly, fasteners 4422 extend generally
vertically
38
Date Recue/Date Received 2022-11-03
between corresponding apertures in brace 440 and brackets 4414 to couple
together
brackets 4414 and brace 4420. Fasteners 4422 extend through isolators 4421 on
bracket
4414. Couplers 4424 are configured to receive a portion of fasteners 4422 to
secure
bracket 4414 to brace 4420. Because rear drive 2076 is coupled to brackets
4414, rear
drive 2076 also is coupled to brace 4420 through brackets 4414.
[000229] The housing of rear drive 2076 further includes second bosses 4418
configured to receive fasteners 4426 in order to couple a forward portion of
rear drive
2076 to upstanding brackets 4428. Illustratively, fasteners 4426 extend
through apertures
in upstanding brackets 4428 and through bosses 4418 of rear drive 2076 in
order to
couple with couplers 4430. Upstanding brackets 4428 extend upwardly from frame
tubes
2172.
[000230] Referring still to Figs. 87A and 87B, rear drive 2076 may be
mounted in
double shear and also mounted in a manner to avoid clamp load loss when the
installation
sequence is followed. To avoid clamp load loss, the following installation
sequence may
be used. First, rear drive 2076 is assembled with frame 2020 by dropping rear
drive 2076
down into the rear envelope between upstanding brackets 4428. Although
upstanding
brackets 4428 may be welded to frame tubes 2172, upstanding brackets 2172
create a
cradle to hold rear drive 2076 in place while fasteners 4426 are then
assembled through
bosses 4418. Next, brackets 4414 are installed in the fore-aft direction into
the envelope
of brace 4420 and fasteners 4422 are then installed. Then, vertical fasteners
4422, which
may be double shear bolts, are added loosely. Fasteners 4426 are tightened
first, then
fasteners 441 are tightened. Lastly, fasteners 4422 are tightened.
Accordingly, fasteners
4412 have no preload loss in the joint and allow some flexibility and
tolerance stack up
with this configuration.
[000231] Referring to Figs. 88-93, the powertrain of vehicle 2 includes a
breather tube
or conduit 4140. Breather tube 4140 is configured to prevent engine oil from
entering the
combustion system of engine 50 if vehicle 2 is in a tip- or roll-over
situation. For example,
at approximately 80 lean relative to vertical, sump oil for engine 50 may
move through
breather tube 4140 and could enter the intake manifold of engine 50, which may
cause
damage to the cylinders and other components of engine 50. As such, there is a
need
39
Date Recue/Date Received 2022-11-03
for breather tube 4140 to mechanically close off this flow path to the intake
manifold during
a roll-over situation.
[000232] Breather tube 4140 includes a first or engine portion 4142
configured to be
coupled with main oil sump 648 of engine 50 (Fig. 25) and a second or intake
portion
4144 configured to be coupled with an intake manifold of engine 50. More
particularly,
first portion 4142 includes a coupler or connector 4146 configured as a quick-
connect
coupler for attaching to sump 648 or other portion of engine 50 and second
portion 4144
includes a coupler or connect 4148 configured as a quick-connect coupler for
attaching
to the intake manifold.
[000233] Additionally, breather tube 4140 includes a check valve 4150
positioned at
an interface 4152 of first and second portions 4142,4144. Check valve 4150
includes a
housing 4154 having a first end 4156 and a second end 4158 and a check ball
4153.
First end 4156 is positioned generally in first portion 4142 of breather tube
4140 while
second end 4158 is positioned generally in second portion 4144 of breather
tube 4140.
Housing 4154 may be a single component configured to house check ball 4153
such that
first and second ends 4156, 4158 may be integrally formed together. In various
embodiments, housing 4154 may be comprised of aluminum tubing or injection-
molded
plastic which is ultrasonically welded together. The materials comprising
housing 4154
and check ball 4153 are configured to withstand high engine oil temperatures
(e.g.,
approximately 150 C) and completely seal hot oil from entering the intake
manifold of
engine 50.
[000234] First end 4156 includes at least one stop feature 4160, configured
as an
indentation or reduced diameter portion of housing 4154, which prevents
movement of
check ball 4153 past this portion of first end 4156. Second end 4158 includes
a seat 4162
configured to receive check ball 4153 when check ball 4153 is within second
end 4158.
Seat 4162, which may be comprised of a rubber material, includes an orifice
4164
extending therethrough and is configured to receive a fluid depending on the
operation
and position of vehicle 2. In one embodiment, the flow area through housing
4154 may
be approximately seven times larger than the flow area through orifice 4164.
Both first
and second ends 4156, 4158 include guides 4166 configured to ensure that check
ball
4153 remains centered within housing 4154 for complete sealing, if needed.
Date Recue/Date Received 2022-11-03
[000235] In operation, and referring to Figs. 92 and 93, if vehicle 2
encounters a tip-
or roll-over situation, check ball 4153 moves towards seat 4162 to prevent oil
from sump
648 flowing into the intake manifold of engine 50 (Fig. 92). However, when
vehicle 2 is
upright and operating along a ground surface, check ball 4153 may move away
from seat
4162 in order to allow gas pressure from the crankcase of engine 50 or other
fluids to
vent during operation of the powertrain (Fig. 93).
[000236] Referring to Figs. 94-96, the powertrain of vehicle 2 includes air
intake
system 608, 2608, as disclosed herein. Air intake system 608, 2608 includes
intake ports
4170 positioned generally adjacent utility bed 2088. Illustratively, intake
ports 4170 are
positioned on right and left sides of vehicle 2 and one intake port 4170 is
configured to
provide air to engine 50 and the other intake port 4170 is configured to
provide air to CVT
52. The incoming air from intake port 4170 to engine 50 is provided for
combustion while
the incoming air from the other intake port 4170 to CVT 52 provides cooling
air for cooling
clutches 978, 980 and the belt.
[000237] Intake ports 4170 each include a filter or other cover 4172
coupled to a
bezel 4174. Bezel 4174 may be defined as part of outer body 80, 2080 and may
receive
filter 4172 (e.g., be removably coupled with filter 4172) or may be integrally
formed with
filter 4172. Ports 4170 face outwardly from vehicle 2 such that ports 4170
face the
ambient air surrounding vehicle 2 and are configured to pull ambient air
therein.
[000238] To minimize noise caused by the incoming air flowing into ports
4170, bezel
covers or blockers 4176 may be positioned along a portion of bezels 4174. More
particularly, because ports 4170 are positioned generally at the same vertical
height as a
portion of the seat back in seating area 22, noise at ports 4170 may be heard
by the
operator and/or passenger; however, bezel covers 4176 deflect sound rearwardly
and
away from seating area 22.
[000239] Illustratively, bezel covers 4176 include an inwardly-facing wall
4176a, an
upper surface 4176b, and a rearwardly-extending portion 4176c. In this way,
bezel
covers 4176 generally surround upper and inner surfaces of bezels 4174 while
leaving
the outer surface of bezel 4174 and filter 4172 fully exposed for receiving
the ambient air.
Bezel cover 4176 may be removably coupled to bezel 4174 through fasteners 4178
extending through at least upper surface 4176b. In this way, bezel covers 4176
may be
41
Date Recue/Date Received 2022-11-03
removed for cleaning and removing mud or dirt accumulations thereon. It may be
appreciated that bezel covers 4176 do not extend into utility bed 2088 and,
therefore, do
not impinge on the available cargo volume or space of utility bed 2088.
[000240] Referring to Figs. 97-99, the powertrain of vehicle 2 includes
exhaust 986,
2986, as disclosed herein. Exhaust 986, 2986 includes muffler 4032 supported
at the
rear end of vehicle 2 and, more particularly, supported by support area 2200.
Exhaust
986, 2986 further includes an exhaust outlet or tailpipe 4180 comprised of a
conduit
portion 4182 and an outlet portion 4184. Conduit portion 4182 may be removably
coupled
or integrally formed with a portion of muffler 4032 and outlet portion 4184 is
fluidly coupled
to muffler 4032 through conduit portion 4182.
[000241] Illustratively, outlet portion 4184 is removably coupled to
conduit portion
4182 at an intersection or coupling location 4188 and is retained on conduit
portion 4182
with at least a removable fastener 4186 (Fig. 98). A collar or other coupling
or retaining
member also may be used to join outlet portion 4184 to conduit portion 4182 at
intersection 4188.
[000242] Outlet portion 4184 may include a plurality of sides which
intersect with each
other. Illustratively, the shape of outlet portion 4184 is defined by four
sides and generally
defines a trapezoid. As shown best in Figs. 97 and 98, a length of an upper
side 4184a
may be greater than that of a lower side 4184b. Left and right sides 4184c,
4184d may
extend between upper and lower sides 4184a, 4184b and are coupled thereto such
that
left and right sides 4184c, 4184d extend diagonally inwards towards centerline
L to couple
with lower side 4184b.
[000243] Outlet portion 4184 is defined as a double-wall outlet which
includes a first
wall segment 4190 extending from and generally colinear with conduit portion
4182 and
a second wall segment 4192 surrounding a portion of first wall segment 4190.
In one
embodiment, first and second wall segments 4190, 4192 are integrally formed
with each
other and, because of that, second wall segment 4192 increases the return edge
of outlet
portion 4184. In this way, first and second wall segments 4190, 4192 radially
overlap
each other to define the double-wall structure. In various embodiments, any
portion of
exhaust 986, 2986 may include an insulated cover or wrapping to shield
adjacent
components of vehicle 2 from the heat produced within exhaust 986, 2986 and/or
to
42
Date Regue/Date Received 2022-11-03
strategically manage the heat within exhaust 986, 2986 at various points along
the
system.
[000244] In one embodiment, exhaust 2986 is a center exhaust such that
outlet
portion 4184 is positioned along centerline L (Fig. 5). However, various
panels of outer
body 80 also may be positioned at this location and, therefore, it is
necessary to ensure
that the temperature of exhaust 2986 at the location of the body panels of
outer body 80
does not exceed a threshold which is detrimental to the body panels. By
configuring
outlet portion 4184 as a double-wall outlet, the cumulative thermal
conductivity of outlet
portion 4184 decreases, thereby protecting the body panels adjacent outlet
portion 4184.
[000245] Referring to Fig. 100, a cooling assembly may be provided with the
powertrain of vehicle 2 in order to provide cooling to the various components
of the
powertrain, such as engine 50. The cooling assembly includes coolant bottle
3000, which
may be similar to coolant bottle 1000 of Fig. 42. Coolant bottle 3000 may be
supported
on support area 2200, as shown in Fig. 66, and, illustratively, may be
supported on tubes
2208 at a position generally adjacent airbox 4030. 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. Lower housing portion 3002b
includes
a notched or recessed portion 3003 positioned adjacent a lower or bottom
surface 3004
of housing 3002.
[000246] Recessed portion 3003 is configured to receive a sensor 3006.
Sensor
3006 is configured to detect the coolant level within coolant bottle 3000.
Based on the
location of recessed portion 3003 and sensor 3006 (i.e., the location adjacent
lower
surface 3004), sensor 3006 can detect when the coolant level in housing 3002
is low.
Sensor 3006 is electrically or otherwise operably coupled to a control system
of vehicle 2
and, therefore, if a controller receives an input from sensor 3006 indicating
that the
coolant level in coolant bottle 3000 is low, the control system may provide a
visual or
auditory alert to the operator. If necessary, the control system may control
vehicle
operation and/or parameters of the powertrain based on the coolant level
within coolant
bottle 3000 and the output of sensor 3006.
[000247] Referring to Fig. 101, the powertrain of vehicle includes fuel
tank 3050
similar to fuel tank 1050 disclosed in Figs. 44 and 45. Fuel tank 3050 may
include a vent
43
Date Recue/Date Received 2022-11-03
conduit 4194 positioned along a portion of frame 2020 and directed towards the
rear of
vehicle 2. More particularly, vent conduit 4194 extends upwardly towards frame
member
2182 and along frame tube 2174 to enter frame tube 2174 at an opening 4196
(also
shown in Figs. 56 and 63-65). Frame tube 2174 is a hollow frame tube which
also
includes an opening 4198 (Figs. 57 and 63-65) at a rear end thereof. Vent
conduit 4194
may extend through opening 4196 and along a length of frame tube 2174 towards
opening 4198. In this way, fuel (e.g., vapor) that is vented from fuel tank
3050 flows
through vent conduit 4194 and into frame tube 2174 at opening 4196. The fuel
that vents
from conduit 4194 into frame tube 2174 then flows rearwardly through at least
a length of
vent conduit 4194 and/or frame tube 2174 and exits frame tube 2174 and vehicle
2 at
opening 4198. As such, vented fuel is directed towards right side of vehicle 2
at frame
tube 2174 and is directed away from heat-producing components (e.g., of the
powertrain),
even when vehicle 2 is traversing on a hill or is leaning, for example, to the
left side. In
other words, the configuration of frame tube 2174, openings 4196,4198, and
vent conduit
4194 ensures that fuel does deviate from the path within frame tube 2174 and
flow
towards a hot area of frame 2020 when vehicle 2 is at certain orientations.
[000248] Referring to Figs. 102 and 103, in operation, the powertrain of
vehicle 2 may
be configured for pull-pull shifting. The powertrain of vehicle 2 further
includes shiftable
transmission 2056 which may be similar to shiftable transmission 56 of Fig. 3.
Shiftable
transmission 2056 is operable by a shifter assembly 2060 which may be similar
to shifter
assembly 60 of Fig. 5. Illustratively, shifter assembly 2060 is operably
coupled to a first
cable 4200 and a second cable 4202 both of which extend between shifter
assembly 2060
and shiftable transmission 2056.
[000249] Cables 4200, 4202 are operably coupled to a pulley 4204 of
shiftable
transmission 2056. At least a portion of cables 4200, 4202 is supported on a
bracket
4206 extending from a housing 4208 of shiftable transmission 2056. Bracket
4206 is
removably coupled to housing 4208 with fasteners 4209. Each cable 4200, 4202
is
coupled to pulley 4204 at a connection location and, as shown best in Fig.
103, cable
4200 is coupled to pulley 4204 at connection location 4210 and cable 4202 is
coupled to
pulley 4204 at connection location 4212. Connection locations 4210, 4212 are
fixed
points on pulley 4204 such that movement of cables 4200, 4202 pulls pulley
4204 at the
44
Date Recue/Date Received 2022-11-03
corresponding connection location 4210, 4212 to cause a shift change in
shiftable
transmission 2056. Pulley 4204 keeps the effective radius of cables 4200, 4202
constant
and, therefore, the shift force also stays constant. By using pulley 4204 and
the two pull
cables 4200, 4202, the force required to shift remains constant.
[000250] Cables 4200, 4202 are configured as pull cables such that movement
in
cable 4200, 4202 pulls on pulley 4204 based on movement of shifter assembly
2060,
compared to known designs which require a combination of pulling and pushing
movements on the transmission bell crank to shift the transmission. By
configuring cables
4200, 4202 as pull cables, the bell crank of traditional shiftable
transmissions may be
eliminated.
[000251] In one embodiment, cables 4200, 4202 are different sizes to ensure
proper
installation on vehicle 2. More particularly, connection locations 4210, 4212
of pulley 4204
are defined as openings with different diameters to corresponding to the
different
diameters of cables 4200, 4202 such that only cable 4200 may be coupled to
pulley 4204
at connection location 4210 and cable 4202 may be coupled to pulley 4204 at
connection
location 4212. Similarly, shifter assembly 2060 also includes differently-
sized openings
corresponding to each of cables 4200, 4202. Further, bracket 4206 also may
include
openings having different diameters such that bracket 4206 receives cable 4200
through
a first opening for coupling with connection location 4210 and bracket 4206
receives cable
4202 through a second opening (having a different diameter than that of the
first opening)
for coupling with connection location 4212.
[000252] In operation, when shifter assembly 2060 is moved to a particular
position
by the operator to indicate the desired gear, either cable 4200 or cable 4202
moves in
response to the movement of shifter assembly 2060. The movement of cable 4200
or
cable 4202 pulls on pulley 4204. The movement of pulley 4204 causes a shift
change in
shiftable transmission 2056. It may be appreciated that because cables 4200,
4202 are
not connected to each other (e.g., because each cable 4200, 4202 has a
separate
connection location 4210, 4212 on pulley 4204), when one cable moves, there is
no
corresponding and opposite movement of the other cable. Instead, both cables
4200,
4202 are configured for a pulling motion on pulley 4204 based on the movement
of shifter
assembly 2060.
Date Regue/Date Received 2022-11-03
[000253] Referring to Figs. 104 and 105, in order to minimize noise and
vibrations
from the powertrain and/or other components or systems of vehicle 2 within
seating area
22, vehicle 2 may include panels 4220. Panels 4220 may be configured as two-
part
panels which include a first portion 4222 and a second portion 4224. First and
second
portions 4222, 4224 may be coupled together in various ways, such as with
adhesive or
mechanical fasteners. First and second portions 4222, 4224 are coupled to
vehicle 2
through fasteners 4226, 4228. Fasteners 4226, 4228 may be dowels, pins, bolts,
screws,
or other removable coupling or locating components.
[000254] Illustratively, first portion 4222 is positioned forward of second
portion 4224
such that first portion 4222 is exposed to seating area 22 while second
portion 4224 is
not. Fasteners 4226 extend through openings 4230 in first portion 4222 and
fastener
4228 extends through an opening 4232 in first portion 4222 in order to couple
with frame
2020 or other portions of vehicle 2 within or defining seating area 22.
[000255] First portion 4222 includes a curved or arcuate wall 4234 and a
linear or flat
wall 4236. Similarly, second portion 4224 includes a curved or arcuate wall
4238 and a
linear or flat wall 4239. Walls 4234, 4238 have complementary shapes and,
therefore,
wall 4234 is generally received within wall 4238. Walls 4236, 4239 also have
complementary shapes and may be in contact with each other.
[000256] First portion 4222 may be comprised of a polypropylene and
fiberglass
material, such as Azdel material, available from Federal Foam Technologies,
Inc. Second
portion 4224 may be comprised of a sound-dampening foam material. In this way,
first
and second portions 4222, 4224 absorb sound and vibrations from other portions
of
vehicle 2 so as to minimize noise and vibrations within seating area 22. The
materials of
first and second portions 4222, 4224 also may be used to reduce the weight of
vehicle 2
compared to other sound-dampening or vibration-absorbing materials.
Additionally,
because at least first portion 4222 is exposed within seating area 22 and,
therefore, is
exposed to water, mud, dirt, and debris that may enter seating area 22, panels
4220 may
be configured as waterproof panels.
[000257] Referring to Figs. 106-111, and as disclosed further herein with
respect to
outer body 80 (Fig. 1), outer body 2080 of vehicle 2 may include various
features. Hood
2082 of outer body 2080 may include a hinge assembly 4240 for coupling a
grille 4242 to
46
Date Regue/Date Received 2022-11-03
various surfaces of hood 2082. Grille 4242 may be used to receive and direct
ambient
air into at least one conduit for components of the powertrain (e.g., an air
intake duct of
CVT 52). Grille 4242 is positioned within an opening 4243 of hood 2082 and,
illustratively,
hood 2082 includes openings 4243 on both the left and right sides thereof to
support two
grilles 4242. Grilles 4242 and the corresponding intake ports at grilles 4242
face laterally
outward from centerline L (Fig. 5) to receive ambient air fora powertrain
component (e.g.,
CVT 52).
[000258] Hinge assembly 4240 includes an enclosure 4246 extending generally
around a perimeter of grille 4242. Enclosure 4246 is coupled to hood 2082
through
fasteners 4248, 4250. More particularly, fasteners 4248 extend through
openings 4252
within enclosure 4246 and receive fasteners 4250 for coupling enclosure 4246
(encompassing grille 4242) to hood 2082.
[000259] Hinge assembly 4240 further includes a deflector panel 4254
coupled to
grille 4242 through an upper panel 4256. Upper panel 4256 extends generally
inwardly
and horizontally from an upper surface of grille 4242 and is positioned below
a portion of
hood 2082. Deflector panel 4254 extends generally vertically and inwardly
relative to
upper panel 4256 and grille 4242 and is coupled to upper panel 4256 at a
living hinge
4258. The pattern of grille 4242 and the position of deflector panel 4254
relative to grille
4242 minimizes the likelihood that debris or water, which may inadvertently
flow through
grille 4242, flows into the air intake conduits coupled to the powertrain.
Instead, if debris
or water flows through grille 4242 and under hood 2082, the debris or water
will contact
an outer surface of deflector panel 4254 and will fall vertically downward and
out of vehicle
2, rather than flowing inwardly under hood 2082 and into the air intake
conduit in fluid
communication with grilles 4242. More particularly, the pattern of grille 4242
prevents
large debris from entering hood 2082 while deflector panel 4254 is inward of
grille 4242
and blocks the line of sight to the conduit (e.g., CVT air intake conduit)
from water spray,
small debris, etc.
[000260] Hinge assembly 4240 further includes a tab 4260 extending from
deflector
panel 4254. Tab 4260 is coupled to deflector panel 4254 at a living hinge
4262. Tab
4260 includes a slot or opening 4264 configured to receive a strap 4266
coupled to
enclosure 4246 and/or grille 4242. Strap 4266 at least partially extends
through opening
47
Date Regue/Date Received 2022-11-03
4264 on tab 4260 and is secured thereto with a clip 4268. In this way,
deflector panel
4254 is coupled to grille 4242 through upper panel 4256, tab 4260, and strap
4266.
[000261] Deflector panel 4254 is further coupled to grille 4242 through an
arm 4270
extending from grille 4242 and/or enclosure 4246 and extending through an
opening 4272
of deflector panel 4254. Arm 4270 may include a retaining feature 4274
configured to
extend through opening 4272 and hook or otherwise retain arm 4270 on deflector
panel
4254.
[000262] Referring now to Figs. 112-114, vehicle 2 may include various
accessories.
For example, vehicle 2 may include a lightbar assembly 4280 coupled to a
portion of cab
frame 2028. Lightbar assembly 4280 may be used with or without a roof for
vehicle 2. In
one embodiment, and where a roof is not included on vehicle 2, lightbar
assembly 4280
is coupled to a frame member 4282 extending generally between frame members
3072.
Illustratively, light bar assembly 4280 is coupled to gussets 4284 which are
coupled to
both frame members 3072 and 4282. Gusset 4284 may have a generally a
triangular
shape which extends between frame members 3072 and 4282. Gusset 4284 includes
openings 4286 configured to receive fasteners 4288 for coupling lightbar
assembly 4280
to cab frame 2028, as disclosed further herein. It may be appreciated that if
a roof is
included on vehicle 2, the roof also may be mounted to cab frame 2028 at
openings 4286
of gussets 4284 such that the roof and lightbar assembly 4280 share common
mounting
locations on cab frame 2028.
[000263] Lightbar assembly 4280 is comprised of at least a lightbar 4290,
mounting
members 4292, and wiring 4294. Lightbar 4290 extends generally along the
length of
frame member 4282 and, in one embodiment, is approximately the same length as
frame
member 4282. In alternative embodiments, lightbar 4290 has a length that is
less than
that of frame member 4282. Lightbar 4290 includes end plates 4296 and a
fastener 4298
extending therefrom. End plate 4296 and fastener 4298 are received within a
recessed
portion 4310 of mounting member 4292 and, more particularly, fastener 4298
extends
through an aperture 4300 of mounting member 4292. Fastener 4298 is coupled to
a
second fastener 4302 to secure lightbar 4290 to mounting member 4292.
48
Date Regue/Date Received 2022-11-03
[000264] Wiring 4294 is electrically coupled to lightbar 4290 and extends
through a
portion of mounting member 4292 and along a portion of frame member 3072 in
order to
couple with a power source of vehicle 2.
[000265] Mounting members 4292 may be diecast components comprised of at
least
a metallic material. Mounting member 4292 includes apertures 4304 which are
configured to receive fasteners 4288 in order to support mounting member 4292
and,
therefore, lightbar 4290 on cab frame 2028. Apertures 4304 are positioned
along a lower
surface 4312 of mounting member 4292. Lower surface 4312 further includes a
slot or
channel 4306 which is configured to receive and conceal a portion of wiring
4294. An
isolator 4308 may be positioned adjacent cab frame 2028 and mounting member
4294 to
minimize vibrational transfer to lightbar 4290.
[000266] Referring now to Figs. 115-126, front suspension assembly 40 is
shown in
greater detail. As noted above, suspension assembly 40 includes upper
alignment or A-
arm 280 (Fig. 126), lower alignment or A-arm 282 (Figs. 115-116), and linear
force
element (LFE) 284 which is shown as a spring over shock (Fig. 12). Lower A-arm
282
includes a forward extension 5000 and a rearward extension 5002 which are
respectively
coupled to couplers 374, 376 and 384, 386 for mounting lower A-arm 282 to
frame 20
(Fig. 8). Forward and rearward extensions 5000, 5002 generally extend
laterally relative
to the longitudinal centerline L (Fig. 5). Forward and rearward extensions
5000, 5002 are
coupled together to define a laterally outer portion 5004 of lower A-arm 282.
Outer portion
5004 illustratively includes a ball joint housing 5006 which is configured to
receive ball
joint 394 (Fig. 13). More particularly, outer portion 5004 includes a recess
5008
configured to receive a portion of ball joint housing 5006 such that ball
joint housing 5006
extends outwardly from outer portion 5004 to define a laterally outermost
extent of lower
A-arm 282. In one embodiment, ball joint housing 5006 may be a forged
component.
[000267] Referring still to Figs. 115-120, lower A-arm 282 may be comprised
of a
plurality of components. Illustratively, lower A-arm 282 is comprised of an
upper stamping
5010, a lower stamping 5012, and an upper plate 5014. Unlike a butted joint
between
stampings 5010, 5012, upper stamping 5010 is coupled to lower stamping 5012 at
overlapping sides 5016 (shown best in Fig. 120) such that upper stamping 5010
and lower
stamping 5012 define a clamshell arrangement. In other words, a lower extent
of upper
49
Date Regue/Date Received 2022-11-03
stamping 5010 extends over and is in contact with an upper extent of lower
stamping
5012 at overlapping sides 5016. Overlapping sides 5016 extend generally the
complete
or full length of upper and lower stampings 5010, 5012 and, illustratively,
extend between
ball joint housing 5006 and couplers 374, 376, 384, 386. Upper and lower
stampings
5010, 5012 may be permanently coupled together with welds, adhesive, or any
other
conventional coupling mechanisms.
[000268] Lower stamping 5012 defines the lowermost surface of lower A-arm
282
while upper stamping 5010 defines at least a portion of the uppermost surface
of lower
A-arm 282. More particularly, an upper surface 5018 (Fig. 115) of upper
stamping 5010
defines the upper surface of lower A-arm 282 along a length of lower A-arm 282
that
extends approximately from upper plate 5014 to couplers 374, 376, 384, 386.
However,
as described further herein, upper surface 5018 of upper stamping 5010 at
outer portion
5004 of lower A-arm 282 may be positioned vertically below or underneath at
least a
portion of upper plate 5014 such that upper plate 5014 defines the upper
surface of lower
A-arm 282 at outer portion 5004.
[000269] As shown in Figs. 115-120, upper plate 5014 is configured to be
positioned
over a portion of upper surface 5018 of upper stamping 5010 at outer portion
5004 and
may be permanently coupled thereto with welds, adhesive, or any other
conventional
coupling mechanism. Upper plate 5014 extends approximately from a recess 5020
to
legs 522, 524. Recess 5020 is configured to generally align with recess 5008
of upper
stamping 5010 and also receives ball joint housing 5006. As shown best in Fig.
118, a
portion of upper stamping 5010 is exposed laterally outwardly of upper plate
5014
adjacent ball joint housing 5006. As such, this tiered configuration of ball
joint housing
5006, upper stamping 5010, and upper plate 5014 allows for a defined weld area
which
allows a weld to penetrate all three surfaces during a single welding
operation.
[000270] Legs 522, 524 extend along an upper surface of a portion of
extensions
5000, 5002, respectively. In this way, upper stamping 5010 and upper plate
5014
collectively define the uppermost surface of lower A-arm 282, where upper
stamping 5010
defines the uppermost surface at extensions 5000, 5002 and upper plate 5014
defines
the uppermost surface at outer portion 5004.
Date Recue/Date Received 2022-11-03
[000271] Upper plate 5014 also includes side walls 5026 which extend along
a
portion of upper stamping 5010 and downwardly towards lower stamping 5012. An
upper
surface 5028 of upper plate 5014 includes an opening 5030, which will be
described
further herein.
[000272] With continuing reference to Figs. 115-120, lower A-arm 282
further
includes a suspension mounting assembly 5032. Suspension mounting assembly
5032
is defined by a gusset plate 5034, a spherical or bearing 5036, and a
retention member
5038, illustrative a C-clip tension member. It may be appreciated that
component 5036
is not a bushing, as may be conventionally used in other suspension
arrangements, and,
instead, is bearing because a bushing would constrain the motion of the shock.
[000273] Gusset plate 5034 may be a forging or may be machined. Gusset
plate 5034
has an opening 5035 (Figs. 117A and 117B) configured to receive bearing 5036
therein.
Bearing 5036 is partially retained within opening 5035 through a small
tolerance or
interference fit and, as such, by forming gusset plate 5034 through forging,
opening 5035
is able to be sized to retain bearing 5036. Retention member 5038 also is
configured to
retain bearing 5036 within opening 5035 of gusset plate 5035. Bearing 5036 is
configured
to couple a lower end of LFE 284 to lower A-arm 282, as is disclosed further
herein.
[000274] Gusset plate 5034 is configured to be received within and extend
through
opening 5030 of upper plate 5014. More particularly, gusset plate 5034 is
configured to
be positioned atop a portion of upper surface 5018 of upper stamping 5010 at
outer
portion 5004 and extends through opening 5030 of upper plate 5014. Because
upper
plate 5014 is coupled to both upper stamping 5010 and gusset plate 5034, upper
plate
5014 helps to join together upper stamping 5010 and gusset plate 5034.
[000275] Opening 5035 of gusset plate 5032 is exposed and configured to
receive
fasteners for coupling with LFE 284. Gusset plate 5032 may be permanently
coupled to
upper stamping 5010 and/or upper plate 5014 with welds, adhesive, or any other
conventional coupling mechanism. For example, at least a portion of a lower
surface
5037 of gusset plate 5034 may be welded or otherwise permanently coupled to
the upper
surface of upper stamping 5010 while at least a portion of lateral surfaces
5039 of gusset
plate 5034 may be welded or otherwise permanently coupled to upper plate 5014.
51
Date Recue/Date Received 2022-11-03
[000276] Referring now to Figs. 121 and 122, a lower end of LFE 284 is
coupled to a
connector, illustratively clevis 298, and connector/clevis 298 is coupled to
gusset plate
5034 to pivotably couple LFE 284 to lower A-arm 282. More particularly, clevis
298
includes two clevis legs 350 which have openings 352 that are configured to
align with
opening 5040 of bearing 5036 to receive a fastener 342 therethrough. A second
fastener
344 is secured to fastener 342 such that fastener 342 extends through openings
352 on
both clevis legs 350 and opening 5040 of bearing 5036 and is partially
received within
second fastener 344 to removably couple clevis 298, and therefore the lower
end of LFE
284, to lower A-arm 282.
[000277] Clevis 350 also includes an upper portion 5042 which is coupled to
both
clevis legs 350 and positioned adjacent the lower end of LFE 284. Upper
portion 5042 of
clevis 350 includes a recessed portion 5044 positioned above and adjacent an
opening
5046 defined between clevis legs 350. Opening 5046 is configured to receive
half shafts
290 and recessed portion 5044 ensures that a predetermined minimum clearance C
is
maintained between half shaft 290 and upper portion 5042 of clevis 298 during
full
compression or rebound of suspension assembly 40.
[000278] More particularly, and referring to Figs. 124 and 125, Fig. 124
shows front
suspension 40 at ride height (i.e., when stopped or during travel across
generally flat
terrain), where front suspension 40 is not at full rebound or full
compression. In Fig. 124
it is apparent that clearance C between upper portion 5044 of clevis 298 and
half shaft
290 is maintained and clevis 298 does not contact half shaft 290. However,
even when
front suspension 40 is at full rebound or compression, as shown in Fig. 125,
clearance C,
albeit smaller than the distance of clearance C of Fig. 124, is maintained
between upper
portion 5044 of clevis 298 and half shaft 290. In this way, clevis 298 does
not make
contact with half shaft 290 regardless of the position of front suspension 40.
[000279] To further maintain clearance C, gusset plate 5034 includes a stop
surface
5048. Stop surface 5048 is a ramped or angled surface which is angled inwardly
towards
legs 5022, 5024 of upper plate 5014 is configured to allow clevis legs 350 to
make contact
before clevis 298 would contact half shaft 290. In this way, stop surface 5048
of gusset
plate 5034 limits the pivot motion of clevis 298 to prevent contact with half
shaft 290.
52
Date Recue/Date Received 2022-11-03
[000280] Because LFE 284 is coupled to lower A-arm 282, lower A-arm 282
experiences loads reacted by LFE 284. More particularly, loads from LFE 284
travel
through bearing 5036 and into spindle 390 (Fig. 12) and, as such, are
experienced by at
least outer portion 5004 of lower A-arm 282. In this way, by including upper
plate 5014
with upper stamping 5010, the stiffness of lower A-arm 282 is increased along
a distance
5056 (Figs. 115 and 119) between ball joint housing 5006 (coupled to spindle
390 (Fig.
12)) and suspension mounting assembly 5032 where the loads from LFE 284 are
experienced. In other words, because upper plate 5014 spans a lateral distance
adjacent
ball joint housing 5006 to suspension mounting assembly 5032, the major loads
experienced at front ground-engaging members 4 and LFE 284 are more evenly
distributed throughout lower A-arm 282 by upper plate 5014 and upper plate
5014
increases the stiffness at these locations of the major loads.
[000281] Referring now to Fig. 126, it may be appreciated that upper A-arm
280 has
a similar configuration to that of lower A-arm 282 in that upper A-arm 280
includes an
upper stamping 5050 and a lower stamping 5052 which overlap each other and are
permanently coupled together at 5054.
[000282] While this invention has been described as having an exemplary
design,
the present invention may be further modified within the spirit and scope of
this disclosure.
This application is therefore intended to cover any variations, uses, or
adaptations of the
invention using its general principles. Further, this application is intended
to cover such
departures from the present disclosure as come within known or customary
practice in
the art to which this invention pertains.
53
Date Regue/Date Received 2022-11-03
