RESEARCH PROJECT:

MAINTENANCE OF THE BRAKE SYSTEM

JORGE BASADRE HIGHER INSTITUTE

MOLLENDO

AUTOMOTIVE MECHANICS III

RESEARCH PROJECT

III

SHIFT: AFTERNOON
PROFESSOR:
AÑO: 2016

MEMBERS:

Vicente Victor Manuel Huaycho Paulet

RESEARCH PROJECT
I. Statement of the problem
1.1 Problem formulation
1.2 Justification
1.3 Delimitation
1.4 Objetivo general y específico

II. Theoretical Framework

2.1 Background of the study

2.1 Scientific theoretical bases
2.3 Definition of basic terms
2.4 Hypothesis of variable system
I: Statement of the problem

The brakes and the stopping system are one of the main active elements of
vehicle in terms of safety and effectiveness in driving under any circumstance.
They are essential when driving, allowing the vehicle to stop, but they suffer a
wear that decreases its effectiveness and eventually forces its replacement.

The most important characteristic of these elements focuses on power.

braking that can be provided to the vehicle, something that is tied to the braking distance.
This will depend on the condition of the elements that compose it: tires and pressure,
shock absorbers and suspension elements, road surface condition, vehicle load… and
of course, state and ability of the driver.

Highlights of the system include front and rear pads and discs, although not
they are not the only ones who suffer wear and tear nor the only ones who force changes as time passes
time and kilometers.

In any case, discs and pads are replaced more frequently. They wear out.
by friction, first the pads, as their friction material is softer, although
sometimes, due to the type of driving or the use of the vehicle (city,
road, load...), the change of the discs goes hand in hand.

The rear brakes, unable to support the weight of the stop due to inertia (weight transfer of
rear tires), are usually smaller and their wear is less than that of the front ones.
Its duration is about double or triple that of those.

The rear brakes, although less common now, may be drum with shoes.
more rudimentary. It usually has lower effectiveness and fatigue resistance, but its duration is
higher.

Pills
The need to make the change is usually indicated by a warning light on the panel.
instruments. The brake pads (can be one, 2 or 4) have
an indicator nipple at a specific distance so that, when its thickness reduces, it touches
the friction surface of the disk, make mass and through a cable reach the witness of the
There are pills with sound indicators that through a metal coupling at a certain
distance, as in the first case, when thickness decreases, they rub against the surface of the disk and
they produce a high-pitched noise that warns of the imminent replacement.
The disks
Due to friction with the brake pad, they also wear out, although with more kilometers. They are replaced.
when the thickness is reduced to the minimum indicated by the manufacturer, upon prior recommendation of a
mechanic.
If the pads are worn out and rub against the disc, they can scratch it even if their thickness is
suitable. A scratched or worn disc with new pads does not fit well, and in
As a consequence, the braking loses effectiveness. Additionally, it causes noises and vibrations in the
stops, and the tablets deteriorate earlier than expected.
Brake pads can also be changed to avoid brake noise, as sometimes they
first they harden and even crystallize. Before that, an attempt is made to clean the dirt caused
due to wear on pliers and tool holders, and applying a copper-based grease on the supports
or contacts of the pads to avoid vibrations and noises, something that can even happen.
changing the disc-pad set.
Brake fluid
This component suffers over time, as it withstands high
temperatures (caused by the friction of the pads and discs) and pressures of the
circuit. It is advisable to change it every 2 or 3 years and to check its condition annually. A
liquid malfunctions cause deterioration, especially of the elements of the braking system that
have or consist of seals or rubber gaskets, such as the brake pump, the
rear brake cylinders and hoses.
To detect the state of the brake fluid, workshops have a tester.
specific that, based on a sample or acting directly in the deposit in the
engine compartment, it boils it to check its boiling temperature, as
minimum of 165º C. Note: the liquid deteriorates, oxidizes and loses qualities, especially for
withstand high temperatures. Depending on its quality, it can be: DOT 3 (205º C), DOT 4 (230º)
C) or DOT 5.1 (260º C).
Drums and shoes
Less and less frequent, although again subjected to wear by the surface of
drum contact. Its duration is high, especially compared to the brakes
forwards.
When replacing them, they must be adjusted. Due to the passage of time and the poor condition of the liquid of
brakes can cause losses or leaks in your system.

FORMULA OF THE PROBLEM

What causes the malfunction of the braking system?

Excessive pedal travel

The causes may be related to the brake fluid (leaks in the circuit, air in
the brake system or brake fluid in poor condition or with a very low level) or the pads, if they are
very worn out. In that case, it is recommended to replace the pads, and if it is something related
with the brake fluid or the hydraulic system. Normally, it will be necessary to clean or bleed

the system and fill with brake fluid.

Fluffy pedal

This can have various causes, with the most likely being issues with the hoses, the
piston of the clamp or the clamp itself, that is stuck. It could also be due to the
air presence in the hydraulic system, or that the brake fluid is deficient or is
mixed with water.

Pedal too hard or offers too much resistance

The most likely causes are that the pills are dirty or stained with grease or
brake fluid, that there is a problem with the caliper piston, problems with the fluid
brakes (we see that this could be the cause of several problems), problems with the
tablets (that are crystallized). It may also be due to the brake discs being
damaged, and if that is the case we should replace them. Another cause that we should not rule out is that

the brake booster has failed, and that's why it's harder for us to activate the pedal.

The pedal seems to have less travel.

The parts that cause the extension or retraction of the moving parts can be
defective, for example, the piston of the main cylinder is unable to return to its place
correctly. It feels like the pedal doesn't easily return to rest. In that case
the simplest thing is to take the car to the workshop and have it checked properly (although in reality,

whenever we talk about brakes, it is advisable to take the car to a specialized place.

At least one wheel is locked.

It will depend on the wheel or how many are locked, but it is a symptom that some part
the system is not working correctly, or it is jammed, obstructed, or swollen.
It may also be due to a defective brake pad or that the brake cable
my hand is hooked, which means it would still be functioning even after releasing the brake.

parking
The brake pedal vibrates or pulses

Without confusing the vibrations that are felt when the ABS kicks in, it can
that we have warped discs or worn (or loose) wheel bearings.
It can also be something more generalized and that we have to replace both pills.
like brake discs. It may also be due to poorly balanced wheels, or to a
knee joint in poor condition.

Loss of braking capacity when hot

Low-quality pills or those that make poor contact, it could even be due to the discs, which
They are very thin (although in stock cars this does not have to be the cause, but it does if
we change them ourselves). It can simply be fading, due to the excess work that
we require the braking system, which loses effectiveness with temperature. In that case
Is it better to use more engine braking, or just cool the brakes?

The car sways to one side

Problem of more complex determination. It may be due to multiple causes, including

that the pads on one side are dirty or impregnated with grease or brake fluid.
It is advisable to replace the entire axle pads. The pads may have crystallized.
It may be due to a problem with the tire pressure, or to faulty ball joints.
state, worn shock absorbers, problems with the discs and many other causes. In
In case this is detected, it is advisable to go directly for a review, and to provide details on the

problem detected.

A squeaking noise is noticeable when braking.

Again, many possible causes. From dirt on the pads (dust, particles
metallic...), that are very worn or of low quality, that rub against the pads
against Cali for missing a piece. It may also be due to the discs, which
they are in poor condition. Again, in the face of these symptoms, it is advisable to quickly go to have them checked.

a glance.
JUSTIFICATION

The system was initially developed for airplanes, which usually have to
brake hard once they have landed. In 1978, Bosch made history when it introduced the
first electronic anti-lock braking system. This technology has become the basis for
all electronic systems that use ABS in some way, such as the
traction and stability controls.

As of today, around 75% of all vehicles manufactured in the world are equipped with the
ABS. Over time, ABS has become commonplace, so that today the great
Most recent model cars and trucks come equipped with it. Somemotorcyclesof
High displacement vehicles also have this braking system. ABS has become standard equipment.
mandatory in all cars manufactured in theEuropean Unionstarting from July 12004,
thanks to a voluntary agreement among car manufacturers. Nowadays, systems are being developed
ofelectric brakethat simplify the number of components and increase their effectiveness.

DELIMITATION

In the year 1936, the idea was patented by the German [Link] was about doing (not
only for cars, but also for trucks, trains, and planes) that it was harder to block a
wheel in a sudden brake, which could achieve greater safety. They were made
tests, but nothing serious was reached until the developed thedigital electronicsat the beginning of
the 70s. Until then, it was materially impossible to carry out as many calculations as I needed
the system and quickly.

Bosch started serious work on the development of ABS in 1964 in collaboration with a
subsidiaryTeldixBut it is in 1970 when the company develops an effective device and with the
possibility of large-scale commercialization. The first generation of ABS had 1,000
components, a figure that was reduced to 140 in the second generation. After 14 long years
development, finally the second generation ABS was ready, which was offered as
a lush and revolutionary option in theMercedes-Benz S-Classfrom the time along with
theMercedes-Benz E-Classand followed by theBMWSeries 7.

GENERAL OBJECTIVE
Perform diagnosis and repair of pneumatic brakes, retarders (hydraulic -
magnetic) and servo-assisted hydraulic brakes, based on checks using the
tools, equipment and the techniques specified by the manufacturer and safety standards
occupational health.
SPECIFIC OBJECTIVES
Explain the physical concepts related to the function and operation of systems
brakes.
Repair hydraulic brake systems of drum and disc types assisted by vacuum.
Repair drum and disc brake systems, pneumatically assisted.
Repair pneumatic brake systems. Repair pneumatic brake actuators.
Repair the different types of vehicle retarders.
Repair multi-disc brake systems used in wheel loaders and motor graders
The purpose of this post is not to detail with full precision all possible causes and
all possible solutions in the braking system. It is more about the intention to know what
We can notice when we press the brake pedal and what it might be due to, and the logical thing is

that when we notice something unusual, we should go check the car in a

specialized workshop. With brakes, just like with tires, there is no playing around.

If the slightest loss of braking effectiveness is noticed, it should be kept in mind that
we have an expense coming up, and if we play to prepare the car and use low-cost spare parts

Quality, we are falling into a serious error, as we may find ourselves with
unpleasant surprises when it comes time to brake when we need it the most.

II; THEORETICAL FRAMEWORK

BACKGROUND OF THE STUDY