路虎底盘系统技术英文培训课件.ppt

1、Whats Changed,Discovery 3,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 4,LAND ROVERDISCOVERY 3 / LR3Introduction Programme,David Holme,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 5,Preliminaries: ,Fire, Toilets, First Aid and Refreshments,COURTESY,NO IMAGING

2、CAPTURE EQUIPMENT PERMITTED,Company Directive C 114,OFFICE AREA,Kitchen,Reception,Stores,Workshop Area,Water Cooler,L,G,C,D,Stores,Work Area,Technical Academy Layout,Seating Area,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 9,INTRODUCTIONS,Whos Who?,INTRODUCTIONS,Previous trainin

3、g programmes Years of Land Rover experience Which company do you work for How long at present company Hobbies / Interests / Humorous Incidents What are your expectations from this programme Duration of introduction 3 minutes,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 11,WORKING

4、 TOGETHER,Programme Commitment,WORKING TOGETHER,Accept a share of responsibility to make the programme work Remember the objectives stay focused on the topical subject Contribute to the programme positively Listen to what others have to say Consider how their ideas can be applied Relate the content

5、to your job function Review and feedback,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 13,Programme Objectives,Summary Overview,Programme Objectives,At programme close delegates will be able to: Explain the service procedures or requirements Describe system module locations Descri

6、be what trims are needed to be removed for module access Explain high level system operation Show T4 functionality and diagnostic changes with a basic example,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 15,Safety and Precautions,Safety First,Workshop Safety,General precautions W

7、orkshop and Personnel - Safety Equipment Guidelines Chemicals and Solvents System Capping Updates Driving and Regulations,Could It Happen To You?,Hand Held Telephone!,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 18,Chassis,Overview of Changes,You Will Be Able To:,Describe the cha

8、nges to the chassis system Explain what serviceable components exist Describe which suspension components are adjustable Use GTR locate geometry data List geometry data settings Locate on GTR service tools associated with the suspension system,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File na

9、me,Slide 20,GTR,Global Technical Resource,GTR,1. General 100 - General Tools and Specifications (Jacking, Stands, etc) 2. Chassis 204 Suspension 206 Braking 211 Steering 3. Powertrain 303 Engine 307 Automatic Transmission 310 Fuel System and Speed Control,GTR,4. Electrical 412 Climate Control 413 In

10、strument Cluster 414 Batteries and Charging 415 Entertainment System 417 Lighting 418 Modules 419 Anti-Theft, Navigation, Telephone, etc 5. Body 501 Body Systems,GTR - Access,The web address for GTR is as follows: ,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 24,Chassis,Notable P

11、oints,Chassis,Hydro formed chassis members,Detachable rear end,Removable support for transfer box replacement,Removable for front differential replacement,VIN scribed just after No2 body mounting,Two 15Kg mass dampers,Why Chassis?,Why is a chassis used rather than a monocoque? Multiple platforms can

12、 be produced from a single chassis,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 27,Suspension,Component Changes,Suspension Systems,All new suspension system for Land Rover Discovery 3 / LR3 Can be either: All coil spring suspension Four corner air suspension Independent double wi

13、shbone configuration front and rear Fabricated arms for durability and robustness Double bonded bushes for optimum reliability Hydrabush for front suspension lower control arm rear to reduce wheel vibrations,Suspension Systems,Front,Rear,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Sli

14、de 30,Chassis,Front Suspension,Front Suspension,Serviceable Hydrabush,Serviceable Double Bonded Bushes (vs Non or Single),Serviceable Ball Joints,Non Serviceable Hub Assembly,Aluminium Protection Guide Sleeve,Service Kits Available,Suspension Systems,Suspension bushes orientation can be any one of t

15、he following: No alignment arrows bush fits in any position Two alignment arrows bush fits either way up One alignment arrow means bush fits in only one direction of alignment Refer to GTR for latest information or changes in process,Front - Upper Control Arm,Ride height sensor bracket / pin,ABS / P

16、ad wear cable bracket,Circlip,Stabiliser Link connection,Bush cut-outs / voids to be 90 degrees opposed to arm split line,Front - Lower Control Arm,Hydrabush,Clashing lock stops,Bush cut-outs / voids to be 90 degrees opposed to arm split line,Front Lower Ball Joint Circlip,Hydrabush,OSF,Replace driv

17、e shaft nut if disturbed,Split line,Front hub not serviceable,Front knuckle,NSF,OSF,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 37,Chassis,Steering Systems,Steering System Layout,Steering Column,I - Shaft,PAS Pump,Reservoir,Pipes,Steering Gear,Steering Angle Sensor,Bulkhead Seal

18、s,V6 Petrol Derivative,Four fixing location to Xcar beam,Steering Angle Sensor (3 fixing location),Column lock,Plastic adjustment lever,Connection to upper I-shaft,Adjustment plates,Breakout capsules,Steering Column,Reach 40 mm Rake 6 adjustment Energy absorbtion system 120 mm ride down capability P

19、anasonic steering angle sensor,Main Features:,Steering System,Cam-bolt fixing to column (In footwell),Plastic sleeve (through bulkhead),Fixing for upper/lower shaft connection in engine bay,Fixing to steering gear,Decoupling mechanism,Heat sleeve,Flexible Coupler,Steering Intermediate Shaft,Two moun

20、ting feet location to chassis frame Change fixings if displaced,Rack pinion connection to I-shaft,Internal hex drive on TREs,Bellows kit available for service,Outer ball joint kit and tie rods available for service,Steering Gear,Steering Gear,One piece Aluminium housing Gun drilled rack bar Rack tra

21、vel: 166mm, turns lock to lock: 3.32, giving 50mm/rev ratio Rack forces: 16kN (30mm bar dia, 52mm piston dia) 110 bar system pressure System ratio 17.8:1,Main Features:,PAS Cooler (clipped in place to radiator),Reservoir (100 filter),Banjo bolt HP connection to pump (with anti-rotation feature),PAS

22、Installations V6 Petrol RHD,Banjo bolt HP connection to pump (with anti-rotation feature),Quick-fit connector (return to cooler),Rubber mounting - NVH isolator,Constant tension clips,PAS Installations V8 Petrol LHD,Banjo bolt HP connection to pump (with anti-rotation feature),Attenuation & twin cham

23、ber hoses on all derivatives,PAS Installations V6 Diesel LHD,Banjo bolt HP connection to pump (with anti-rotation feature),Attenuation & twin chamber hoses on all derivatives,Latch plate fixing to gear,Support brkts mounted to gear body,PAS Installations V8 Petrol RHD,LP port,HP port,Pressed-on pull

24、ey,Mounting,PAS Pump,PAS Fluid: Texaco 14135,Pump pressure: 114 4 bar Flow rate: 9.2 0.5 l/min Theoretical displacement: 9.6 cc/rev Pump speeds: 910 rpm / 7563 rpm (V6 Petrol) 865 rpm / 8645 rpm (V8 Petrol) 1043 rpm / 7367 rpm (V6 Diesel) Max/Min working oil temperature: -40C to +120C PAS Fluid: Tex

25、aco 14135,Main Features:,PAS Pump,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 50,Chassis,Rear Suspension,Rear Suspension,Service Kits Available,Knuckles Serviceable,Bushes Serviceable,Adjustable Camber,Change Nut If Disturbed,Rear - Lower Control Arm,Bush cut-outs / voids to be

26、90 degrees opposed to arm split line,RLCA - Front Bush,Rear Lower Control Arm,Bush cut-outs / voids to be 90 degrees opposed to arm split line,Handbrake Cable Bracket,Damper Bracket,Split line,Rear Upper Control Arm,RUCA Front Bush,Rear Knuckle Assembly,Upper ball joint,Push in force 2 tons,Three se

27、rvice tools for remove and install,Lower ball joint,Replaced on vehicle,Five service tools for remove and install,Replace drive shaft nut if disturbed,Rear Knuckle Assembly,Rear Toe Link,Outer Cross Axis Joint,Anti Rotation Axial Joint,Toe Adjustment,Adjustable,Rear Toe Link,Toe Adjuster,Hexagon for

28、m for adjustment,Anti Rotation feature,Cross Axis Joint,Spring and Damper Assemblies,Spring over damper design Twin tube damper element same as Defender, Range Rover Front spring is a cylindrical, single rate, with open helix ends and an upper isolator seat Rear spring is a double pigtail, with dual

29、 rates and upper isolator seat,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 60,Suspension Worksheet - A,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 61,Suspension Review,Questions and Answers,Worksheet A - Review,What section for ball joint data? GTR section:

30、204 What service tools required for removing upper ball joint assembly? 204-503/2 and 204-719/5 What service tools required for installing upper ball joint assembly? 204-530/1 and 204-530/2 What specific instructions were provided for installing upper ball joint? Align cut out to indentation alignme

31、nt mark Position circlip 90 from indentation alignment mark,Worksheet A - Review,What are the geometry setting for the front suspension? Castor: 4 25 30 Camber: -30 45 Total Toe: -10 10 How is rear camber adjusted? Rear knuckle upper ball joint cam bolts What must be observed when installing lower c

32、ontrol arm bushes? Void cut outs must be opposed to the LCA split line What setting for toe link replacement? 13mm between gaiter and bracket,7/28/2020 12:09 AM, Land Rover 2003. Presenter / File name,Slide 64,Chassis,Tyre Pressure Monitoring,Initiators Wheel Sensors Instrument Pack TPMS ECU Fascia

33、Switch Pack,TPMS Schematic,Fuse 32 (15 amp) Battery Supply,Fuse 36 (5 amp) Ignition Supply,Power Supply,125 Khz,FULL SIZE SPARE WHEEL,LF INITIATOR,LF INITIATOR,WHEEL SENSOR,WHEEL SENSOR,ECU,315 Mhz 433 Mhz,LF INITIATOR,LF INITIATOR,CLUSTER,CAN BUS,Rx,WHEEL SENSOR,WHEEL SENSOR,TPMS,TPMS,TPMS,System O

34、peration: On driving off, the ECU polls each road wheel with LF (125 KHz) signal via the initiator in turn (starting LHF going clockwise) They respond directly to the TPMS ECU with a RF transmission (315 or 433 MHz) containing a unique ID, pressure, temperature and acceleration information As each w

35、heel responds, it is assigned a position on the vehicle and monitored for the remainder of the drive cycle in that position The initiator is not used again unless the speed reduces to below 12 mph (20 km/h) for 15 minutes,TPMS,Tyre Pressures: Up to GVW: Fronts = 33 PSI - Rears = 42 PSI Post - Positi

36、on Identification: Sensors transmit once a minute whilst the vehicle is driving (Spare every 13 hours) There are two levels of driver warning Amber indicator at 25% deflation (Front 33 PSI = 25 PSI) (Rear 42 PSI = 31 PSI) Red indicator at 35% deflation (Front 33 PSI = 21 PSI) (Rear 42 PSI = 27 PSI)

37、On High-Line vehicles, the message centre replaces the red warning indicator and provides additional information about the position of the affected wheel(s),TPMS,Fault Detection: If the ECU or one-or-more sensor fails, the amber tell-tale will be lit and a warning displayed on the message centre,“Ty

38、re Pressure Monitoring Sensor Fault”,Tyre Pressure Monitoring Sensor Fault,TPMS,A warning will be displayed if RF interference around the vehicle is too strong for the system to work, but will be cancelled when interference subsides,When the sensor battery is low, it sends out a flag to the control

39、module, the ECU can be checked to determine if a sensor needs replacing,Tyre Pressure Monitoring Sensor Fault,Message Centre and Lamps,Warning Lamps,Amber warning indicator = 25% Red warning indicator = 35%,Low Line System High Line Message Centre,TPMS,Customer Education: Tyre pressure need to be ch

40、ecked and adjusted when cold Pressure reduces as air cools If checking whilst hot then pressure should be set higher to compensate (not recommended though) Temperature Change Examples:,18C (65F) 33 PSI 12C (55F) 32 PSI 7C (45F) 31 PSI 1.6C (35F) 30 PSI -3.8C (25F) 29 PSI,Fascia Switch,A fascia mount

41、ed switch informs the TPMS ECU of the different vehicle / tyre loading LED on = Light Tyre Loading LED off = Heavy Tyre Loading Preference = LED off (Normal Position) Pressing the switch and indicating the additional load increase cancels the switch LED and resets the system to the higher threshold,

42、NAS One threshold ROW Two thresholds,TPMS,Tyre Changing: The bead breaker must not be used within 90 degrees of the valve In order to reduce the risk of sensor damage during tyre removal and refitting, the sensor must be positioned correctly in relation to the fitting arm If the sensor is removed, t

43、he nut, seal and washer must be replaced and the sensor fixing torque must be adhered to Sensor components are available as service parts,Mounting tool position to start tyre fitting,Valve initial position,Rim,Tyre,Fitting machine direction of rotation,Red area: Tyre bead in wheel well,Green area: T

44、yre bead above wheel rim,Tyre Removal,TPMS,Wheel Learning: Replacement Wheels If new wheels with sensors are fitted to a running position, they will be learnt when the vehicle is first driven and no other action is required Spare Wheels If a new sensor is fitted in the spare position, the unique ID

45、must be programmed diagnostically or the wheel will not be monitored It will be provided on a label for complete assemblies, and is also printed on the casing of each sensor If a known running wheel is exchanged with the spare, it will then be monitored as the spare,7/28/2020 12:09 AM, Land Rover 20

46、03. Presenter / File name,Slide 83,Chassis,Air Suspension System,Air Suspension Schematic,RHD,Air Suspension Relay and Fuses,Relay R7 (70 amp - Black - N.O) (BJB) Fuse 26 (20 amp - Yellow) (BJB) - Battery Fuse 51 (5 amp - Brown) (CJB) - Ignition,Air Suspension,Design Objectives: Deliver Fast acting

47、system over large wheel travels lifting and lowering Consistent performance over all vehicle environments - Altitude Electronically controlled system with enhanced on-board diagnostics Provide vehicle levelling independent of load Multiple ride heights Off Road Standard Access (Crawl) Enhanced off r

48、oad performance,No Motorway Height Lowering,Air Suspension Units,Spring over damper design concept Twin tube damper with double bonded lower bush and welded spring seat Double bonded, dual path top mount with separate single bonded rebound bush Front and rear air springs have a 2.5mm rubber sleeve w

49、ith a nylon cross fibre ply crimped to steel piston and top mount The rubber sleeve has an aluminium cylinder crimped around it Polyurethane spring aid / bump stop,NSR,Air Suspension,Air Spring and Damper Assemblies: Key Features Guided Air Spring over damper due to working pressures Improved ride c

50、haracteristic over non guided Air Springs Burst pressure 35 bar Normal running pressures: Front : 8 - 10 bar Rear : 5 8 bar Max spring pressure (Full bump GVW) circa 27 bar) Decoupled Air Spring guide Allows greater damper articulation without trapping air sleeve,Air Suspension,Air Spring and Damper

51、 Assemblies: Key air spring sealing points Piston to damper body Key Service Issues: Component / system depressurisation Component / system re-pressurisation Care required when removing / refitting air spring / damper assembly to ensure seals are not damaged,Air Suspension - ECU,Unique component Loc

52、ated behind facia on body side panel (A post drivers side) Fixed to vehicle body with two plastic clips and single M8 screw Requires calibration if replaced,Height Control,Long Press = Locked = Crawl Mode,Driver Interface,Heights indicated by unique symbols Off road 55 mm above Standard Access 50 mm

53、 down from Standard Reselectable whilst vehicle moving Extended Mode Automatically selected Crawl indicated as “Locked at Access” Direction of movement indicated by arrows Flashing lamps not used during normal operation customer feedback response Remote operation via customer configurable hand set 1

54、 of 3 available settings Additional information via message centre,Speed data for each mode shown in workbook,Message Centre,Example Message Centre Display,Fault Indicator,Indicator Amber = Minor Fault Detected,Indicator Red = Major Fault Detected,Air Supply Unit Assembly,Evolution of existing unit

55、for Land Rover application Located on left hand chassis rail (in front of rear wheel) Assembly comprises: Air compressor with integral Air drier Isolation mounts Exhaust Valve (electrically switched pilot operated) Double temperature sensors maximising duty cycle available ECU controlled Max pressur

56、e: 16.8 bar (nominal) Acoustic box for noise control,Reservoir,Twin chamber design to EU pressure vessel guidelines Volume: 9 litres Working pressure: 17.5 bar (23 max) Located off body mount brackets on left hand chassis rail,Air Suspension,Valve Blocks: Front axle block assembly mounted on front b

57、umper 2x front individual solenoid operated corner valves 1x front cross link valve,Rear axle block assembly mounted on LHR spring tower 2x rear corner valves and 1x cross link valve as per front Voss air fittings,Air Suspension,Reservoir valve block assembly: Pressure sensor in manifold to monitor

58、spring pressures and reservoir pressure Mounted on isolators to reduce valve noise Voss air fittings,Air Suspension,Air Harness: Intake & exhaust pipes larger Intake via filter at rear of vehicle (Discovery II But on dry side) Twin chamber foam filled silencer for intake and exhaust noise control,Inside rear quarter panel,Air Suspension,Air Suspension Schematic,Air Suspension,Height Sensors: Contacting technology unit 4 Height sensors per vehicle Supply voltage = 5 volts Output voltage = 0.5v to 4.5v Body down = Voltage up Or Arm up = Vo