Material ini dimaksudkan untuk digunakan oleh peserta-peserta training dan tidak menutup
Kemungkinan untuk terus diperbaharui.
Secara khusus hal ini ditujukan untuk personal dari Mercedes Benz grup atau jaringannya.
Dilarang mencetak ulang, memperbanyak atau menterjemahkan sebagian atau keseluruhan isi material ini
Disusun oleh :
Central Training Department – Product Training
Edisi ke 1 11/2009
Total halaman : 99
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 1 PT Mercedes-Benz Distribution Indonesia CTD
DAFTAR ISI Halaman
1. PENGERTIAN DASAR
1.1 Tujuan dari pengereman 1
1.2 Percepatan / Perlambatan 2
1.3 Perlambatan ″ a ″ dan koefisien gesek ″ R ″ 3
1.4 Tekanan ″ p ″ gaya ″ F ″dan luas penampang ″ A ″ 5
1.5 Perbandingan gaya 6
2. SISTIM REM
2.1 Sistim rem manual 7
2.2 Sistim rem dengan tenaga bantu 8
2.3 Sistim rem dengan bantuan udara tekanan penuh 9
2.4 Rem roda 10
3. PERLENGKAPAN
3.1 Silinder utama 12
3.2 Silinder rem 13
3.3 Rakitan rem saluran ganda 14
3.4 Rakitan rem dengan bantuan tenaga 15
3.5 Rem cakram 16
4. RANCANG BANGUN SISTIM REM UDARA TEKAN
4.1 Prinsip kerja 17
5. ABS 21
6. SISTIM REM SECARA TERUS MENERUS 24
7. DIAGRAM FUNGSI DAN SIMBOL-SIMBOL
7.1 Elemen dasar dari simbol-simbol 27
7.2 Simbol dasar 29
7.3 Katup rem parkir 31
8. PENGENAL HUBUNGAN-HUBUNGAN
9. KOMPRESOR
9.1 Kompresor 33
9.2 Prinsip kerja 34
10. KOMPRESOR UDARA DENGAN PENGGERAK RODA GIGI
10.1 Susunan Komponen 35
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 2 PT Mercedes-Benz Distribution Indonesia CTD
11. PENGERING UDARA MENYATU DENGAN PENGATUR TEKANAN
11.1 Pengatur tekanan knorr 36
11.2 Prinsip kerja 37
11.3 Posisi pengisian (cut-in) 38
11.4 Posisi pembuangan (cut-off) 39
11.5 Posisi pengisian udara dari luar 40
12. PENGERING UDARA TUNGGAL
12.1 Pengering udara tunggal 41
12.2 Posisi kerja 42
12.3 Posisi buang 43
13. KATUP PENGAMAN 4 JALUR
13.1 Katup pengaman 4 jalur dengan 7 saluran 44
13.2 Prinsip kerja 45
13.3 Posisi menutup 46
13.4 Posisi kerja 47
13.5 Posisi mengamankan 48
13.6 Susunan komponen knorr 49
13.7 Susunan komponen wabco 50
14. TANGKI UDARA TEKAN DAN PIPA PENGHUBUNG
14.1 Tangki udara 51
14.2 Hubungan sumbat 52
15. KATUP REM KAKI
15.1 Katup rem kaki 2 jalur 53
15.2 Prinsip kerja 54
15.3 Posisi bebas 55
15.4 Posisi pengereman awal 56
15.5 Posisi pengereman penuh dan pembuangan 57
15.6 Susunan komponen wabco 58
16. KATUP RELAY
16.1 Posisi awal bekerja 60
16.2 Posisi bekerja 61
16.3 Posisi pembuangan 62
16.4 Susunan komponen wabco 63
17. SILINDER REM KOMBINASI
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 3 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 1.PENGERTIAN DASAR 01.2009
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 4 PT Mercedes-Benz Distribution Indonesia CTD
1.2 Percepatan/Perlambatan
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 5 PT Mercedes-Benz Distribution Indonesia CTD
1.3 Perlambatan "a"dan koefisien gesek " R "
Ketergantungan dari percepatan dan koefisien gesek Jadi koefisien gesek tergantung dari kondisi permukaan jalan dan ban
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 6 PT Mercedes-Benz Distribution Indonesia CTD
µR "
Koefisien gesek "µ
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Ketidak tergantungan koefisien gesek terhadap luas ------------------------------------------------------------------------------------------------------------------------
Permukaan/penampang. ------------------------------------------------------------------------------------------------------------------------
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Ketergantungan koefisien gesek terhadap gerakan. ------------------------------------------------------------------------------------------------------------------------
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 7 PT Mercedes-Benz Distribution Indonesia CTD
1.4 Tekanan " p " , Gaya " F " dan Luas penampang " A "
F
P =
A
1Pa = 1N/m²
1 bar = 1kg/cm²
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 8 PT Mercedes-Benz Distribution Indonesia CTD
1.5 Perbandingan gaya
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 9 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 2.SISTIM REM 01.2009
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 10 PT Mercedes-Benz Distribution Indonesia CTD
2.2 Sistim rem dengan tenaga bantu
Sistim rem dengan bantuan kevakuman Pompa vakum Menghasilkan kevakuman maksimal 0,8 bar
Silinder rem utama Menghasilkan tekanan hidrolis sebagai fungsi dari tekanan
pedal
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 11 PT Mercedes-Benz Distribution Indonesia CTD
2.3 Sistim rem dengan bantuan udara tekan penuh
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 12 PT Mercedes-Benz Distribution Indonesia CTD
2.4. Rem roda
Rem tromol
Rem cakram
Rem tersebut diatas prinsip kerjanya adalah merubah energi menjadi panas
Sehingga dengan demikian maka keausan akan terjadi.
Rem tromol
Rem simplex
Ciri-ciri utama
•Satu sepatu rem utama (Leading)
•Satu elemen penggerak untuk kedua sepatu rem
•Satu titik pendukung untuk setiap sepatu rem
Keuntungannya:
Sangat kuat,reaksi rem yang merata.
Efek pengereman maju dan mundur sama besar
Kerugiannya :
Pengaruh servo yang rendah memerlukan tekanan kontak yang tinggi
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 13 PT Mercedes-Benz Distribution Indonesia CTD
Rem duplex ganda
Ciri-ciri utama :
Keuntungan nya :
Kerugiannya :
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 14 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 3. PERLENGKAPAN 01.2009
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Tugas : ----------------------------------------------------------------------------------------------------------------------
Untuk menghasilkan tekanan hidrolik. ----------------------------------------------------------------------------------------------------------------------
Prinsip kerja : ----------------------------------------------------------------------------------------------------------------------
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Bila silinder rem di injak, torak menekan cairan untuk menghasilkan tekanan
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hidrolik yang dikirimkan melalui pipa-pipa rem ke silinder-silinder rem ----------------------------------------------------------------------------------------------------------------------
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 15 PT Mercedes-Benz Distribution Indonesia CTD
3.2 Silinder rem
Tugas :
Prinsip kerja
1 Rumah 7 Pegas
2 Kap pelindung 8 Mangkok /dudukan pegas
3 Torak 9 Pelat pegas
4 Baut 10 Torak dengan perlengkapan penyetel
5 Karet geser (roda gigi penyetel)
6 Pelat 11 Baut penekan
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 16 PT Mercedes-Benz Distribution Indonesia CTD
3.3 Rakitan rem saluran ganda
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Tugas : ----------------------------------------------------------------------------------------------------------------------
Untuk menggerakkan dan mengontrol pengiriman cairan dengan ----------------------------------------------------------------------------------------------------------------------
menggunakkan udara tekan ----------------------------------------------------------------------------------------------------------------------
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 17 PT Mercedes-Benz Distribution Indonesia CTD
3.4 Rakitan rem dengan bantuan tenaga (kevakuman udara )
Tugas :
Prinsip kerja :
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 18 PT Mercedes-Benz Distribution Indonesia CTD
3.5 Rem Cakram
Ciri-ciri utama :
Torak hidrolis pada kedua sisi rem akan menekan kampas rem mendorong
rem cakram pada waktu rem di operasikan
Ciri-ciri utama :
Torak hidrolik menekan kampas rem mendorong rem cakram .Kampas rem
yang sebelahnya juga menekan rem cakram secara mekanis (kaliper)
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 19 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 4. RANCANG BANGUN SISTIM REM UDARA 01.2009
Kompresor ----------------------------------------------------------------------------------------------------------------------
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Pengatur tekanan ----------------------------------------------------------------------------------------------------------------------
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Menyatu dengan pengering udara
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Katup pengaman 4 jalur ----------------------------------------------------------------------------------------------------------------------
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Tangki udara ----------------------------------------------------------------------------------------------------------------------
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 20 PT Mercedes-Benz Distribution Indonesia CTD
Komponen Tugas
Katup Rem kaki Memberikan pengontrolan tekanan pengereman secara halus dan
bertahap
Silinder rem
Mengoperasikan pengereman pada roda.
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 21 PT Mercedes-Benz Distribution Indonesia CTD
Komponen Tugas
Solenoid dan switch Bus Stop Mengirimkan tekanan udara ke silinder rem kombinasi pada saat pintu
brake. dibuka,dan membuang udara dari silinder rem kombinasi bila pintu
ditutup
(Bila fungsi diaktifkan)
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 22 PT Mercedes-Benz Distribution Indonesia CTD
Komponen Tugas
Pengering udara Meyerap kandungan air yang ada pada udara tekan
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 23 PT Mercedes-Benz Distribution Indonesia CTD
5. ABS
Tugas
Perlengkapan tambahan
Prinsip kerja :
Sensor dan ring pulsa pengukur kecepatan roda dan mengirimkan pulsa
listrik ke kontrol unit .
Jika roda ada indikasi akan terkunci, tekanan pengereman yang
dikirimkan akan dirubah oleh katup solenoid.
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 24 PT Mercedes-Benz Distribution Indonesia CTD
5. ABS
Tugas :
Prinsip kerja
Peraba (1) dihubungkan pada gandar dengan bantuan roda pulsa (2)
mendeteksi gerakkan putar roda . Pulsa yang dibangkitkan pada sensor
diteruskan ke pengontrol elektronik (3) yang mendapatkan kecepatan
roda .
Pada saat yang sama kontrol elektronik menentukan kecepatan
kendaraan .
Dari semua informasi ini kontrol elektronik selalu menghitung
pertambahan
Kecepatan (+b) atau nilai-nilai pengurangan kecepatan (-b) termasuk bila
pengereman terjadi slip. Bila suatu nilai terlampaui, katup kontrol
solenoid (4) bekerja.
Bila suatu nilai slip terlampaui, katup kontrol solenoid (4) bekerja. Hal ini
menyebabkan tekanan didalam silinder rem dibatasi atau bahkan
dikurangi dengan demikian maka roda-roda dijaga pada nilai slip yang
terbaik.
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 25 PT Mercedes-Benz Distribution Indonesia CTD
Langkah kontrol
Komentar :
Pemberian tekanan rem
(oleh pengemudi) Langkah kontrol :
Aksi pengerman
terjadi Pengemudi menginjak pedal rem tekanan rem naik. Kendaraan mulai
berkurang kecepatannya, seimbang dengan kecepatan pada saat
tersebut .
Aksi pengerman terlalu Aksi pengerman normal
Dengan demikian kecepatan roda terpisah dengan kecepatan kendaraan
besar(resiko terkunci) Pengereman terjadi tanpa
ABS diaktifkan Mengaktif kan ABS Meksipun kendaraan masih dalam tingkat pengereman yang stabil (slip
pengereman sebesar 10 sampai 30 % ) kontrol pengereman sudah
diakifkan melalui solenoid.
Tekanan rem di rendahkan
Efek permulaannya adalah tekanan pengereman tiba-tiba turun hingga
Langkah kontrol dapat katup solenoid diaktifkan selayaknya dan menahan pada tahap menjaga
Aksi pengereman merendah diulang 3-5 kali perdetik tekanan. Kecepatan roda naik lagi, sinyal selanjutnya mengakibatkan
tergantung pada tahanan
yang terjadi antara
tekanan akan di naikkan lagi melalui katup solenoid. Kecepatan roda
Tekanan rem di tahan ban/permukaan jalan dan akan mendekati lagi kecepatan kendaraan.
tanggapan serta berapa kali
pembangunan tekanan Langkah kontrol selanjutnya diketahui oleh kontrol unit (micro
Aksi pengereman merendah pengereman komputer) dan secara terus menerus ditentukan ulang sebagai fungsi
dari reaksi dinamis yang sesuai dengan kecepatan roda dengan
memperhitungkan perbedaan koefisien gesek. Frekuensi kontrol
Menaikkan tekanan maksimum adalah 3-5 langkah.per detik
Pengereman dengan pulsa
Secara berturut-turut (mengatur
naiknya secara bertahap)
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 26 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 6. SISTIM REM SECARA TERUS MENERUS 01.2009
Tipe
PELAMBAT HIDRODINAMIK
Sebuah pelambat hidrodinamik terdiri dari roda turbin dan roda pompa,seperti
kopling hidrodinamik.Ketika pelambat dijalankan sebuah pompa memompa
minyak hidrolik kedalam rumah – rumah sebagai akibat dari gerakkan berputar
roda pompa,minyak mengalir melalui sudu – sudu dari roda turbin sehingga
diperlambat jadi panas.Energi dari gerakan ini dirubah menjadi energi panas.
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 27 PT Mercedes-Benz Distribution Indonesia CTD
Pelambat listrik rem memanfaatkan garis-garis gaya listrik Pelambat hidrodinamik
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 28 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 9. DIAGRAM FUNGSI DAN SIMBOL -SIMBOL 01.2009
DIAGRAM FUNGSI
hubungan tekanan
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 29 PT Mercedes-Benz Distribution Indonesia CTD
9.1 Elemen dasar dari simbol - simbol
Sumber tekanan
Saluran kerja
Saluran kontrol
Selang
Kabel listrik
Hubungan saluran
Pegas
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 30 PT Mercedes-Benz Distribution Indonesia CTD
a. Umum
Pengoperasian dengan tenaga otot b. Tombol
c. Tuas Pengenalan media
d. Pedal penekanan
Udara tekan
Hidrolik
Arus tekanan searah
Tekanan naik
Tekanan turun
Celah stopper
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 31 PT Mercedes-Benz Distribution Indonesia CTD
Simbol dasar
Kompresor
A. Pompa
B. Udara tekan
C. Pengoperasian secara mekanis
A. Tiga saluran
B. Dua posisi pemindahan
C. Pengoperasian secara mekanis
Arah dari panah menunujukan aliran udara tekan dari saluran kesaluran
didalam peralatan
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 32 PT Mercedes-Benz Distribution Indonesia CTD
D. Kedudukan dasar
Hubungan pada saluran 1 di tutup,saluran 2 berhubungan dengan
ventilasi (3)
E. Posisi pemindahan
Untuk menerangkan cara kerja maka seluruh simbol digeser satu halaman
penampang (field). Hubungan yang menunjukkan titik mana yang
berhubungan ditunjukkan melalui titik yang tepat : Saluran 1 berhubungan
dengan saluran 2 Ventilasi 3 tertutup.
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 33 PT Mercedes-Benz Distribution Indonesia CTD
Katup rem parkir untuk pengoperasian pegas rem (bertahap) dan pengontrol ( EC)
Arti dari simbol
Beberapa alat kombinasikan berbentuk satu unit dan didalam garis terputus-
putus .Rem parkir untuk pegas penggerak katup 3/2 arah= katup tambahan
untuk pengontrol gandengan (pengetesan EC)
Kedua alat ini digerakkan didalam oleh tuas dan dikembalikan ke posisi
semula oleh pegas-pegas.
Penomoran dari saluran-saluran penghubung diberikan diluar dari garis –
garis yang terputus-putus.
Katupnya memiliki :
-. Satu saluran masuk 1
-. Dua saluran keluar 21 dan 22
-. Satu ventilasi 3
Posisi tuas : :
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 34 PT Mercedes-Benz Distribution Indonesia CTD
Pengenal hubungan-hubungan
Arti dari kode kode nomor pada saluran : -----------------------------------------------------------------------------------------------
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0 -Hubungan luar (atmosfir) -----------------------------------------------------------------------------------------------
1 -Udara tekan masuk -----------------------------------------------------------------------------------------------
2 -Udara tekan keluar -----------------------------------------------------------------------------------------------
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3 -Hubungan ke atmosfir (ventilasi)
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4 -Pengontrol hubungan (komando) -----------------------------------------------------------------------------------------------
5 -----------------------------------------------------------------------------------------------
6 -----------------------------------------------------------------------------------------------
7 - Hubungan anti freeze (anti beku) -----------------------------------------------------------------------------------------------
8 -Hubungan pelumas kompresor -----------------------------------------------------------------------------------------------
9 -Hubungan air pendingin kompresor -----------------------------------------------------------------------------------------------
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Pembuat perlengkapan menstandarisasikan perlengkapan dengan -----------------------------------------------------------------------------------------------
Mengunakan : -----------------------------------------------------------------------------------------------
- DIN 24300 ( sama dengan standar MB ) -----------------------------------------------------------------------------------------------
- DIN 74235 (standarisasi yang di sederhanakan ). -----------------------------------------------------------------------------------------------
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Gambar -gambar didalam kolom berikut dibawah ini menunjukkan
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keterangan yang dimaksudkan didalam pengeklompokan standar sesuai -----------------------------------------------------------------------------------------------
versi-versi nya : -----------------------------------------------------------------------------------------------
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 35 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 9. KOMPRESOR 01.2009
Pabrik pembuat :
Wabco
Tugas :
Menghisap dan memampatkan udara
1. Katup pengiriman
2. Torak dengan batang torak
3. Poros engkol
4. Katup hisap
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 36 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 9. KOMPRESOR 01.2009
Torak bergerak ke bawah memasukan udara melalui katup masuk dan mendorong melalui katup keluar menuju ke sistim rem.
No hubungan 0 2
Catatan,
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 37 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 10. KOMPRESOR UDARA DENGAN PENGERAK RODA GIGI 01.2009
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 38 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 11. PENGERING UDARA MENYATU DENGAN PENGATUR TEKANAN 01.2009
Tugas:
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 39 PT Mercedes-Benz Distribution Indonesia CTD
11.2 Prinsip kerja
Tekanan udara pada saluran 21 juga menekan diaphragma pada pengatur tekanan,
Pada posisi pengisian, saluran 1 dan 21 berhubungan.
pada posisi pembuangan, saluran 1 dan 3 berhubungan.
No hubungan 1 12 21 22 3
Catatan .
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 40 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 11. PENGERING UDARA MENYATU DENGAN PENGATUR TEKANAN 01.2009
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 41 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 11. PENGERING UDARA MENYATU DENGAN PENGATUR TEKANAN 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 42 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 11. PENGERING UDARA MENYATU DENGAN PENGATUR TEKANAN 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 43 PT Mercedes-Benz Distribution Indonesia CTD
12. PENGERING UDARA TUNGGAL
Tugas :
Mengeringkan udara tekan untuk mencegah terjadinya kondensasi air di
sistim udara tekan
Prinsip kerja
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 44 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 12. PENGERING UDARA TUNGGAL 01.2009
1.Saringan
2.Granulate
3.Katup satu arah
4.Nosel
5.Tangki regenerasi
6. Katup memompa ban
7.Katup pengatur tekanan
8.Katup pembuangan
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 45 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 12. PENGERING UDARA TUNGGAL 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 46 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 13. KATUP PENGAMAN 4 JALUR 01.2009
Tugas :
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 47 PT Mercedes-Benz Distribution Indonesia CTD
13.2 Prinsip kerja :
No hubungan 1 21 22 23 24 25 26
Jalur 21 bocor motor mati >.4,5 0 >.4,5 > 4.5 > 4,5 > 4,5 > 4,5
Catatan.
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 48 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 13. KATUP PENGAMAN 4 JALUR 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 49 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 13. KATUP PENGAMAN 4 JALUR 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 50 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 13. KATUP PENGAMAN 4 JALUR 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 51 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 13. KATUP PENGAMAN 4 JALUR 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 52 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 13. KATUP PENGAMAN 4 JALUR 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 53 PT Mercedes-Benz Distribution Indonesia CTD
14. TANGKI UDARA TEKAN DAN PIPA PENGHUBUNG
Tangki udara tekan ialah penjamin utama yang terdiri dari satu dan dua --------------------------------------------------------------------------------------------------------------
ruang penampung udara --------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------
Sebuah plat pengenal /keterangan terletak pada masing-masing tangki --------------------------------------------------------------------------------------------------------------
udara. --------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------
Keterangan plat meliputi : --------------------------------------------------------------------------------------------------------------
Nama alamat penyalur --------------------------------------------------------------------------------------------------------------
Nomor seri pabrik --------------------------------------------------------------------------------------------------------------
Tahun pembuatan --------------------------------------------------------------------------------------------------------------
Maksimum tekanan sistim yang di ijinkan dalam " BAR " --------------------------------------------------------------------------------------------------------------
Kapasitas dalam liter --------------------------------------------------------------------------------------------------------------
Kode pengenal --------------------------------------------------------------------------------------------------------------
Simbol pengetesan --------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------
Pipa udara tekan --------------------------------------------------------------------------------------------------------------
Pipa-pipa tombac atau baja misalnya digunakan untuk daerah-daerah yang --------------------------------------------------------------------------------------------------------------
suhunya sangat tinggi .Pipa plastik digunakan pada daerah-daerah lainnya. --------------------------------------------------------------------------------------------------------------
Pipa pipa tombac atau baja misalnya pada kompressor udara. --------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------
Pipa-pipa plastik Tekanan pecahnya ± 60 bar
Material Polymide 1 atau 2
Tahan terhadap suhu ± 80° C
Pipa tersebut seluruhnya mempunyai ketahanan terhadap bahan kimia
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 54 PT Mercedes-Benz Distribution Indonesia CTD
14.2 Hubungan sumbat
1. Penghubung
2. Seal ring (merah)
3. Sea ring (hitam))
4. Mur
5. Seal ring mur
6. Kunci penjepit
7. Elemen elastis
8. Rumah penghubung
Catatan :
Perhatian terhadap pengunci anti putar khususnya pada bagian
yang bergerak (contoh pada gambar).
Selama cincin penunjuk masih terlihat, itu berarti nipel tidak
terpasang cukup dalam.
Momen pengikatan :10 Nm
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 55 PT Mercedes-Benz Distribution Indonesia CTD
15. KATUP REM KAKI
Tugas :
memasukan dan Membuang udara tekan dari tangki ke silinder rem pada
roda depan dan belakang.
5.01 Tangki
20.01 Silinder rem kombinasi
20.02 Silinder rem
13.02 Katup rem kaki (service brake)
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 56 PT Mercedes-Benz Distribution Indonesia CTD
15.2 Prinsip kerja
Udara tekan di kirim melalui katup-katup rem kaki hingga ke silinder rem roda -roda melalui jalur -jalur udara tekan sesuai dengan besarnya
pembukaan katup katup
No hubungan 11 12 21 22 3
Rem di fungsikan
sepenuhnya
Posisi pengemudian
10±0,2 Bar
Catatan.
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 57 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 15. KATUP REM KAKI 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 58 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 15. KATUP REM KAKI 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 59 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 15. KATUP REM KAKI 01.2009
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 60 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 15. KATUP REM KAKI 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 61 PT Mercedes-Benz Distribution Indonesia CTD
16. KATUP RELAY
a. Suplay udara
b. Tekanan control
c. Tekanan pengereman
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 62 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 16. KATUP RELAY 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 63 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 16. KATUP RELAY 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 64 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 16. KATUP RELAY 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 65 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 16. KATUP RELAY 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 66 PT Mercedes-Benz Distribution Indonesia CTD
17. SILINDER REM KOMBINASI
Prinsip kerja
Tugas : No hubungan 11 12
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 67 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 17. SILINDER REM KOMBINASI 01.2009
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 68 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 17. SILINDER REM KOMBINASI 01.2009
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 69 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 17. SILINDER REM KOMBINASI 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 70 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 17. SILINDER REM KOMBINASI 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 71 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 18. SILINDER REM DEPAN 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 72 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 18. SILINDER REM DEPAN 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 73 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 18. SILINDER REM DEPAN 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 74 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 19. PENYETEL REM OTOMATIS 01.2009
Meneruskan tensi tenaga silinder rem ke poros-poros nok rem menjaga Menyetel kesesuaian mekanis dari gejala langkah pengereman roda yang
secara tetap celah/speling antara sepatu rem dan tromol berlebihan. Bila rem dilepas, kemudian celah sepatu rem dengan tromol di
stel pada nilai yang benar.
Pemeriksaan :
1. Lengan pengontrol
2. Tuas
3. Nok pengatur
4. Sudut bebas roda
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 75 PT Mercedes-Benz Distribution Indonesia CTD
19.2 Penyetel rem otomatis “ Wabco “
Meneruskan tensi tenaga silinder rem ke poros-poros nok rem menjaga Menyetel kesesuaian mekanis dari gejala langkah pengereman roda yang
secara tetap celah/speling antara sepatu rem dan tromol berlebihan. Bila rem dilepas, langkah dan kemudian speling sepatu rem di
stel pada nilai yang benar.
Pemeriksaan :
1. Plat penyetel
2. Pen
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 76 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 19. PENYETEL REM OTOMATIS 01.2009
Pertama
Pasang penyetel otomatis, dan perhatikan tanda panah pada bagian tuasnya
yang menununjukkan arah dari pengereman, dan juga tanda pada bagian
badannya yang harus searah dengan tanda pada permukaan “ S “
Catatan :
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 77 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 19. PENYETEL REM OTOMATIS 01.2009
Kedua
Catatan :
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 78 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 19. PENYETEL REM OTOMATIS 01.2009
Ketiga
Putar baut setelan mekanis searah jarum jam sehingga lubang pada
tuas penyetel bertemu tepat dengan lubang pada tuas silinder rem
Catatan :
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 79 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 19. PENYETEL REM OTOMATIS 01.2009
Keempat
Berikan gemuk pada pen tuas dan pasangkan, harus dapat masuk dengan
tanpa tegangan .Lalu tekan pelat penyetel (unit control) keatas searah
dengan arah gerakan tuas pada saat pengereman hingga terasa ada tahanan
(karena telah menyentuh stopper didalamnya) ikat baut (gandar depan) atau
mur (gandar belakang)dengan momen 20-25 Nm
Catatan :
Periksa apakah pelat penyetel (unit control) telah menyentuh sedikit pada
penahan kedudukannya, sehingga pada saat diikat tidak ada tegangan
kebengkokan pada pelat penyetelnya, stel bila perlu dengan menggunakan
beberapa pilihan washer kompensasi (0.5 – 1.0 mm gandar depan) atau stel
mur penyetelnya (gandar belakang )
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 80 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 19. PENYETEL REM OTOMATIS 01.2009
Kelima
Putar baut penyetel mekanis searah jarum jam sehingga kampas rem
menyentuh tromol rem.Kemudian putar balik berlawanan arah jarum jam
sebanyak satu putaran penuh
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 81 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 19. PENYETEL REM OTOMATIS 01.2009
Keenam
Tekan rem kaki beberapa kali dan periksa bekerjanya penyetel otomatis,
setiap terjadi penekanan rem kaki harus terjadi gerakan menyetel pada baut
penyetel mekanisnya (di tandai dengan gerakan kunci yang dipegang
lemah searah jarum jam)
Gerakan menyetel ini harus berhenti bila nilai kerenggangan antara kampas
rem dengan tromol telah tercapai
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 82 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 19. PENYETEL REM OTOMATIS 01.2009
---------------------------------------------------------------------------------------------------------------------------
Perhatian ---------------------------------------------------------------------------------------------------------------------------
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1 Bilamana penyetel otomatis ini distel dengan benar maka penyetelan ---------------------------------------------------------------------------------------------------------------------------
secara periodik tidak diperlukan lagi.Cara pemasangan/penyetelan ---------------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------------
yang keliru akan mengganggu bekerjanya penyetel otomatis ini ---------------------------------------------------------------------------------------------------------------------------
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2 Untuk menjamin penyetel otomatis ini agar dapat bekerja dengan ---------------------------------------------------------------------------------------------------------------------------
sempurna maka di rekomendasikan bahwa kampas rem yang baru ---------------------------------------------------------------------------------------------------------------------------
bubut dahulu untuk disesuaikan dengan diameter tromol. ---------------------------------------------------------------------------------------------------------------------------
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3 Sesudah kampas rem diganti, kembalikan posisi cam “ S “ pada ---------------------------------------------------------------------------------------------------------------------------
kedudukannya dan lanjutkan ke langkah no 5 dan no 6 “ instruksi cara ---------------------------------------------------------------------------------------------------------------------------
penyetelan dan pemasangan “ ---------------------------------------------------------------------------------------------------------------------------
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4 Bila penyetel otomatis mempunyai nipel gemuk maka lakukan ---------------------------------------------------------------------------------------------------------------------------
pelumasannya sesuai dengan petunjuk/pedoman pemeliharaan dan ---------------------------------------------------------------------------------------------------------------------------
pelumasan.Bila ada baut penutup yang berulir (bukan nipel) maka ---------------------------------------------------------------------------------------------------------------------------
pelumasannya harus dengan bongkar /pasang penyetel otomatis ---------------------------------------------------------------------------------------------------------------------------
secara keseluruhan. ---------------------------------------------------------------------------------------------------------------------------
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 83 PT Mercedes-Benz Distribution Indonesia CTD
20. KATUP REM TANGAN
Tugas :
Sistim rem parkir /rem kedua dibuat untuk menahan kendaraan agar tetap
diam walaupun pada kondisi jalan menurun oleh gaya dorong mekanis.
Jika sistim rem kaki tidak berfungsi masih memungkinkan untuk
mengoperasikan rem secara bertahap dengan menggerakkan
katup rem tangan
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 84 PT Mercedes-Benz Distribution Indonesia CTD
20.2 Prinsip kerja
Gaya pengereman dari rem parkir dihasilkan oleh pegas spiral pada silinder rem.
Pada posisi pengemudian, udara bertekanan dari katup 4 jalur dialirkan ke katup rem parkir menuju relay ,
Udara yang stand by di relay yang berasal dari katup 4 jalur dialirkan ke silinder rem parkir Ini mengakibatkan pegas tertekan dan rem akan bebas.
Pada posisi pengereman, udara yang mengalir ke katup relay dikeluarkan melalui saluran ventilasi pada katup rem parkir
Udara dari silinder rem parkir kemudian keluar melalui saluran ventilasi yang berada pada katup relay sehingga pegas pada silinder rem parkir mendorong
ke posisi pengereman.
No hubungan 11 21 3
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 85 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 20. KATUP REM TANGAN 01.2009
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Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 86 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 20. KATUP REM TANGAN 01.2009
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 87 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 21. DIAGRAM FUNGSI REM NEW OH1518 01.2009
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 88 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 21. DIAGRAM FUNGSI REM NEW OH1518/LEGEND 01.2009
1.01 Kompresor
4.03 Katup pengaman 6 jalur
5.01 Tangki udara
6.13 Pengering udara menjadi satu dengan katup pengatur tekanan
10.1 Sensor / switch tekanan
13.02 Katup rem kaki
14.01 Katup rem tangan /Parkir
18.01 Relay
20.06 Silinder rem tunggal
20.05 Silinder rem motor
22.01 Silinder rem kombinasi
33.01 Katup magnet /solenoid
35.05 Kopling pengisian tunggal
38.02 Nipel tempat pengetesan
39.02 Silencer /peredam suara
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 89 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 21. DIAGRAM FUNGSI REM NEW OH1518 01.2009
21.2 Latihan
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 90 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 21. DIAGRAM FUNGSI REM OH1518 01.2009
Lembar latihan :
Pada diagram fungsi di halaman sebelumnya terdapat jalur-jalur yang sudah diberikan kode-kode huruf.(contoh A)
Tuliskan di dalam lembar latihan ini besarnya tekanan udara pada jalur masing-masing huruf .
a) Posis jalan /motor hidup tekanan dalam sistim pada cut off/pembuangan.
Huruf A B C D E F G H I J K L
Tekanan
b) Rem parkir di fungsikan dengan pegas sedang berfungsi mengerem / motor mati, tekanan dalam sistim pada saat cutoff/pembuangan
Huruf A B C D E F G H I J K L
Tekanan
c) Rem kaki diinjak penuh rem parkir bebas/motor hidup, tekanan dalam sistim pada saat cut off/ pembuangan
Huruf A B C D E F G H I J K L
Tekanan
Tekanan
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 91 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 22. PENGETESAN SISTIM UDARA TEKAN 01.2009
PENTING !!!!!!!! Sebelum melakukan pengetesan perhatikan hal hal sebagai berikut :
1. Ganjal roda-roda kendaraan agar tidak bergerak
2. Hidupkan motor sampai mencapai temperatur kerja
3. Periksa kerenggangan antara sepatu rem dan tromol
4. Naikkan tekanan udara dalam sistim dan pasang seluruh sambungan sambungan yang diperlukan untuk pengetesan
(lihat petunjuk pentunjuk untuk menghubungkan tekanan.)
Tekanan buka Tekanan tutup
Regulator 10±0,2 Bar 9±0,3 Bar
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 92 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 22. PENGETESAN SISTIM UDARA TEKAN 01.2009
CUT-OFF (Pembuangan)
• Pasang manometer pada titik (A)
• Hidupkan motor sampai regulator terbuka/udara terbuang dari regulator ke udara luar
CUT-IN (Pengisian)
• Pasang manometer pada titik (A)
• Hidupkan motor sampai udara terbuang dari regulator ke udara luar (cut-off)
• Kurangi tekanan dari sistim sedikit demi sedikit melalui titik (A)
• Perhatikan pembuangan pada regulator sampai tidak ada udara yang terbuang ke udara luar
• Lihat tekanan yang terbaca pada manometer dan isi pada tabel
PENGUKURAN DATA PENGUKURAN HASIL PENGUKURAN
CUT-OFF/PEMBUANGAN 10,0±0,2 Bar
CUT-IN/PENGISIAN 9,0±0,3 Bar
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 93 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 22. PENGETESAN SISTIM UDARA TEKAN 01.2009
• Matikan motor
• Buang udara di sistim dengan cepat menggunakan katup untuk memompa ban pada titik (A) sampai 0 Bar
• Periksa tekanan yang terbaca pada manometer dan isi pada tabel
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 94 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 22. PENGETESAN SISTIM UDARA TEKAN 01.2009
• Isi tekanan sistim sampai pada tekanan maksimum dan perhatikan kenaikan tekanan pada manometer
• Tekanan pada sirkuit yang lain akan terisi lebih dulu baru kemudian sirkuit 23 terisi
• Sirkuit 23 akan terisi bila tekanan pada sirkuit yang lain mencapai 7,5 Bar
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 95 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 22. PENGETESAN SISTIM UDARA TEKAN 01.2009
• Isi tekanan sistim sampai pada tekanan maksimum dan perhatikan kenaikan tekanan pada manometer
• Tekanan pada sirkuit yang lain akan terisi lebih dulu baru kemudian sirkuit 24 terisi
• Sirkuit 24 akan terisi bila tekanan pada sirkuit yang lain mencapai 7,5 Bar
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 96 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 22. PENGETESAN SISTIM UDARA TEKAN 01.2009
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 97 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 22. PENGETESAN SISTIM UDARA TEKAN 01.2009
• Kurangi tekanan pada titik B perlahan-lahan sampai lampu peringatan pada instrumen menyala
• Kurangi tekanan pada titik C perlahan-lahan sampai lampu peringatan pada instrumen menyala
22.8 Pengetesan penurunan tekanan setiap sekali pedal rem diinjak penuh
• Pasang manometer pada sirkuit 21 dan 22
• Catat penurunan tekanan pada manometer.Penurunan maksimum setelah pedal rem di tekan penuh adalah 0,7 Bar
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 98 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 22. PENGETESAN SISTIM UDARA TEKAN 01.2009
• Pasang manometer pada silinder rem depan dan silinder rem kaki belakang
• Tekan pedal rem dengan SST sampai tekanan yang masuk ke silinder roda sebesar 3 Bar
(Posisi pedal rem jangan berubah-ubah selama pengetesan)
• Setelah satu menit catat penurunan tekanan yang terjadi pada manometer
• Pasang manometer pada silinder rem depan dan silinder rem kaki belakang
• Tekan pedal rem perlahan –lahan dan perhatikan kenaikan tekanan pada rem belakang
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 99 PT Mercedes-Benz Distribution Indonesia CTD
Group 42 22. PENGETESAN SISTIM UDARA TEKAN 01.2009
1.Shim
2.Cam S
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 100 PT Mercedes-Benz Distribution Indonesia CTD
22.12 Pengukuran drum brake (rem tromol)
PENGUKURAN
Maksimum diameter dalam tromol yang diijinkan mm 414,02
Diameter dalam tromol normal mm 410,0-410,2
Repair 1 mm 411,5-411,7
Repair 2 mm 413,0-413,2
Radius ujung dalam mm 3,0
Kekasaran permukan Rt 14
Maksimum kemiringan per 100 mm mm 0,05
Maksimum ketidak bulatan mm 0,10
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 101 PT Mercedes-Benz Distribution Indonesia CTD
22.13 Pengukuran ketebalan sepatu rem/kanvas
NORMAL mm 17,7-18,0
KETEBALAN SEPATU REM(A) REPAIR 1 mm 18,7-19,0
REPAIR 2 mm 19,7-20,0
KETEBALAN SEPATU REM MINIMUM mm 6,0 – 8,0
PANJANG mm 18,8 – 19,6
DIAMETER mm 7,78 – 8,0
RIVET
GAYA AWAL kg 20-40
GAYA PRIVETAN kg 2200-2600
CELAH SEPATU REM DENGAN TROMOL mm 0,7
Sistem Rem Kendaraan Niaga New OH 1526 / Edisi 1 102 PT Mercedes-Benz Distribution Indonesia CTD