Components of Brake System
1. Brake Pedal
The driver applies a braking initial force upon it by his foot.
The brake pedal is located on the floor to the left of the
accelerator.
2. Brake booster
• Uses an engine's intake manifold depression to boost pedal
effort, is often inserted between the pedal and the master
cylinder.
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3. Master Cylinder
The master cylinder is the central unit in which hydraulic
pressure is developed. Pressure from the driver’s foot pressing
on the brake pedal is transmitted to the master cylinder piston.
Master cylinders have become very reliable and rarely
malfunction; however, the most common problem that they
experience is an internal leak.
Figure 1: 5 Master Cylinder
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4. Brake fluid
Brake fluid is a special oil that has specific properties. It is
designed to withstand cold temperatures without thickening as
well as very high temperatures without boiling.
Brake fluid must meet standards that are set by the Department
of Transportation (DOT).
Any mineral or petroleum-based oils in even the smallest
amounts will swell and destroy the rubber cups and seals in the
system.
Warning: Brake fluid is poison. Keep it away from skin and
eyes. Do not allow brake fluid to splash on painted surfaces
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There are two types of brake fluids
1. Polyglycol
Clear to amber in color
Is a solvent and will immediately being to dissolve paint
One characteristics is hygroscpic (propensity to attract water which
reduce boiling point)
2. Silicon
Is purple in color
It is not hygroscopic (not rest and corrosion problem)
Has higher boiling point, then used in higher heat applications
It is not harm paint when it comes in contact with it
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it is more difficult to bleed air from hydraulic system)
DOT Grades
There are 3 grades of brake fluid which are determined by
Federal Motor Vehicle Safety Standards
Fluid grades are rated by the minimum boiling point for both
pure fluid (day) and water contaminated fluids (wet)
DOT 3 –Polyglycol
Min boiling point-401 oF, dry, 2840F wet
Blends with DOT 4
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DOT 4- Polyglycol
Min boiling point 446 oF, dry, 311 oF wet
Blends with DOT3
DOT 5- Silicone
Min boiling point-550oF dry, 356 oF wet
Compatible by law with DOT 3 &4 but will not
blend with them
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5. Brake Fluid Reservoir
Master cylinder has a reservoir for brake fluid. The reservoir
cover is vented to allow fluid expansion or contraction with
out forming pressure or vacuum.
The brake fluid level will drop slightly as the brake pads wear.
Brake fluid must maintain a very high boiling point. Exposure
to air will cause the fluid to absorb moisture which will lower
that boiling point.
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6. Brake Lines
The brake fluid travels from the master cylinder to the wheels
through a series of steel tubes and reinforced rubber hoses.
Rubber hoses are only used in places that require flexibility, such
as at the front wheels, which move up and down as well as steer.
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7. Brake System Valves
A. Proportioning valve or Equalizer Valve
These valves are mounted between the master cylinder and the
rear wheels. They are designed to adjust the pressure between the
fronts and rear brakes depending on how hard you are stopping.
The shorter you stop, the more of the vehicle's weight is
transferred to the front wheels, in some cases, causing the rear to
lift and the front to dive.
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B. Pressure Differential Valve
This valve is usually mounted just below the master cylinder and
is responsible for turning the brake warning light on when it
detects a malfunction. It measures the pressure from the two
sections of the master cylinder and compares them.
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C. Combination Valve
The Combination valve is simply a proportioning valve and a
pressure differential valve that is combined into one unit.
8. Wheel Cylinder
The wheel cylinder consists of a cylinder that has two pistons, one on
each side. Each piston has a rubber seal and a shaft that connects the
piston with a brake shoe. Wheel cylinders must be rebuilt or replaced if
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they show signs of leaking.
9. Drum Brakes
A drum brake is a brake that uses friction caused by a set of shoes
or pads that press outward against a rotating cylinder-shaped part
called a brake drum. These shoes are made of stamped steel and
have brake linings either riveted or bonded to the outer surface.
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Types of Drum Brake
A. Leading trailing shoe drum brake
In this type, the forward shoe is held stationary at the bottom and
pushed against the drum by the wheel cylinder at the top. As the
drum rotates, this leading shoe is pulled tighter into the drum and
tends to rotate with the drum
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B. Two leading shoe drum brake
This system is arranged with two single-acting wheel cylinder
instead of a one double-acting cylinder as leading trailing and
duo servo types.
Each cylinder forces one end of its shoe outwards and a self-
energizing effect is imported to each shoe due to drum rotation.
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C. Duo Servo Drum Brake
The tops of the shoes rest against a single anchor pin. The
bottoms of the shoes are linked together by a floating adjusting
screw. The shoe towards the front and the rear of the vehicle is
the primary and secondary shoe.
The top of the primary shoe tends to pull into the drum and move
downward. The bottom of the shoe then pushes the adjusting
screws rearward.
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Main components of the drum brake
Anchor
Retraction springs
Back plate
Brake-shoes
Brake lining
Brake drums
Parking-brake lever
Wheel cylinder
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Advantages of drum brakes
It is protected against dirt to a large extent.
It is an easy matter to install a mechanically operated parking
brake.
friction Lining generates a torque, which presses the brake shoe
more firmly against the drum wall and therefore boosts, the
braking action.
Disadvantage of drum brakes
There is a problem of in the disposal of lining dust.
There is heat dissipation problem.
Drum brakes suffer badly from fading,
17 Relining work takes longer than on the disc brake
10. Disc brakes
Disc brake consists of two main parts: the disc, also called the
rotor, and the caliper assembly. The disc rotates with the wheel
hub. In front wheel brakes the caliper is bolted to the steering
knuckle, in rear-wheel brakes the caliper is bolted to the axle
flange. The caliper assembly includes a hydraulic cylinder, piston
& the brake pads.
When the brake is applied, pressure from the master cylinder
forces the pistons against the pads, which are then forced against
the disc. This produces a clamping action, which slows or stops
the disc.
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Components of Disc Brake
Rotor/Disk
Wheel hub
Stationary caliper
Friction pad
Caliper Pistons
Piston Seals
Pad Wear Indicator
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A. Disc Rotor
Generally, the disk rotor is made of gray cast iron, and either
Solid
Ventilated
The third style rotor can be either the ventilated or solid type
which incorporates a brake drum for an integral parking
brake assembly.
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B. Brake Pad
Brake pads consist of friction materials bonded or riveted
(glued) to a metal plate.
Anti-squeal shim :Prevents unusual noise as the brake pad
vibrates at the time of braking.
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C. Pad wear indicator
A pad has adopted on some models that produces high
screeching noise when the pad is worn down to a predetermined
thickness.
The purpose is to warn the driver and prevent damage to the
rotor if the brake pad wear further.
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D. Disc brake calipers
The typical disc brake caliper assembly has caliper housing, one
or more pistons seal on each piston, a dust boot for each piston,
and two brake pads.
There are three types of disc brake calipers.
Fixed caliper
Floating caliper
Sliding caliper
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1. Fixed caliper
• It has a pair of pistons to push the disc/rotor in the both sides.
• The caliper is rigidly attached to steering knuckle or other
stationary vehicle part.
• Only the pistons and pads move when the brakes are applied.
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2. Floating caliper
Has only one piston, located on the inboard side of the disc.
The caliper moves or “floats” on rubber bushings on one or two
steel guide pins.
Some floating calipers have two pistons on the inboard side of
the disc.
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3. Sliding caliper
The principle of operation of a sliding caliper is the same as that
of a floating caliper. The mounting bracket is bolted to the
steering knuckle. The brake pads are held in the bracket whit
two retaining pins.
The cylinder housing is attached to the yoke, and the yoke is
free to slide on the mounting bracket. When the brakes are
applied, hydraulic pressure pushes against the piston in the
cylinder housing. The piston pushes the inner brake pad against
the inner sides of the rotor.
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11. Parking Brakes
The parking brake (emergency brake) system controls the rear
brakes through a series of steel cables that are connected to
either a hand lever or a foot pedal.
On drum brakes, the cable pulls on a lever mounted in the
rear brake and is directly connected to the brake shoes.
Disk brakes on the rear wheels add additional complication for
parking brake systems.
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Parking brake lever types
1. Release lever
2. Pedal
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12. Brake booster
The brake booster is mounted on the firewall directly behind
the master cylinder and, along with the master cylinder, is
directly connected with the brake pedal.
The purpose is to amplify the available foot pressure applied to
the brake pedal so that the amount of foot pressure required to
stop even the largest vehicle is minimal.
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Air Brake systems
In air brake systems, the braking force exerted by the driver is
reinforced by compressed air stored in air cylinders.
Air brake systems are classified according to their construction;
single- circuit brake systems
dual-circuit brake systems
Single-circuit brake systems
Single-circuit brake systems are no longer installed in
commercial vehicles.
In these systems, the braking energy is transmitted via a single
transmission device (compressed air lines) with no back-up.
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Dual-circuit brake system
If the main brake circuit fails, the vehicle can
still be braked by means of the secondary brake
system.
The law demands that it should still be possible
to brake at least two wheels, located on
different sides of the vehicle, if one brake circuit
fails.
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The Components of an Air Brake System
Compressor
Pressure regulator and air drier
Regeneration tank
Four-circuit protection valve
Compressed-air tank
Foot-operated brake valve
ALB regulator
Pressure converter
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Brake cylinder
Compressor
Compressed air is used to transmit force in an air brake
system. The source of the compressed air is a
compressor (1). A compressor is designed to pump air
into a reservoir which results in pressurized air.
It is piston-cylinder type.
It is usually driven by V-belt from the engine, and runs
continuously.
On the; suction stroke, the piston draws fresh air in
through the suction valve via the engine intake or its
own air cleaner.
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1. Cylinder bead
2. Intermediate plate with inlet and
outlet valves
3. Cylinder
4. Piston
5. Connecting rod
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Pressure regulator
Purpose
The pressure regulator conducts the
compressed air constantly being supplied by
the air compressor as long as the vehicle
engine is running either into the air reservoirs
or into the open.
In this manner, it regulates the supply
pressure of the compressed-air brake system
36 which remains within the operating range. i.e.
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Antifreeze pump
Purpose ;The antifreeze pump injects
antifreeze alcohol into the brake system so
that the water vapor which is contained in the
intake air and condensate does not freeze thus
prevents the normal operation of the brake
system components.
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Four-circuit protection valve
It distributes compressed air to the individual
brake circuits.
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Air reservoir
Purpose;
It is used for storing the air compressed by
the air compressor
Due to the storage of air in the air reservoir;
It is possible to use more compressed air over
a short period than can be supplied by the air
compressor
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Service-brake Valve
Purpose ;The dual-circuit service-brake valve
controls two independent pneumatic service
brake circuits in a tractor vehicle and by way of
the trailer-control valve the service brake
system of the trailer.
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Combi-brake cylinder
Purpose
It is a component of the service brake system
and parking brake system; and actuates the
wheel brakes for both systems.
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