DIKLAT PKB

DASAR
BRAKE SYSTEM

1. Structure and Function

1) Brake system

Service brake

Braking control

Booster

Braking force
transmitting part

Hydraulic brake

Master cylinder

Oil

Not equipped

Oil

Wheel cylinder

Oil

Wheel cylinder

Oil

Wheel cylinder

Equipped with booster

Vacuum servo or

(vacuum servo/air servo) Master cylinder

Oil

Air over hydraulic brake

Brake valve

Air

Full air brake

Brake valve

air servo
Air servo + relay
valve
Air (relay valve), Air
brake chamber

S cam

HYDRAULIC AIR BOOSTER

HYDRAULIC VACUUM BOOSTER

RESERVOIR
TANK

RESERVOIR
TANK

AIR COMPRESSOR
MASTER
CYLINDER

AIR MASTER

MASTER
CYLINDER

AIR TANK

SAFETY
CYLINDER

HYDROMASER

VACUUM TANK

SAFETY
CYLINDER

BRAKE SHOE
BRAKE SHOE
WHEEL CYLINDER

WHEEL CYLINDER

AIR OVER HYDRAULIC BOOSTER

BRAKE VALVE

AIR COMPRESSOR
BRAKE VALVE

AIR TANK

AIR BRAKE

AIR COMPRESSOR

AIR TANK
RELAY VALVE

BRAKE MASTER
BRAKE CHAMBER
RESERVOIR TANK

BRAKE SHOE
WHEEL CYLINDER

CAM SHAFT

BRAKE SHOE

BACK

SISTEM REM

SISTEM REM

Anti-Lock Brake System (ABS)

Anti-Lock Brake System (ABS)

(1)Brake valve

(2)Brake booster(air over type)

PUSH ROD

RETURN SPRING

HYDRAULIC PISTON

RELAY VALVE

POWER PISTON

When Not Operating

To wheel
cylinder

When Operating

When operating

(3)Relay valve
From brake valve

When pressure is balanced

From air tank

To air cylinder

When released

Exhaust

(4)Air compressor
To air tank (Air dryer)

SUCTION

DELIVERY

From
Pressure
regulator

UNLOADER

(5)Pressure regulator

Adjust screw
Spring

Rod

Piston
Valve
Filter

2) Brake unit
(1)Brake types

Leading/trailing-shoe brake

Two-leading-shoe brake
(single action type)

Two-leading-shoe brake
(dual action type)

Duo servo brake

Brake efficacy coefficient

10

Duo servo

Two-leadingshoe brake

Leading/trailingshoe brake

Disk brake
0

0.1

0.2

0.3

0.4

0.5

Friction coefficient

Drum

2. Troubleshooting
1. Procedure for Investigating Service Brake Failure
1) Foreword
Maximum braking force

Friction force between the tires and the road surface

2) Understanding and confirming trouble phenomena

(1) Running conditions when trouble occurred
(2) Braking conditions
(3) Load conditions
(4) Frequency of occurrence
(5) Other
What were the road conditions?

3) Vehicle check prior to investigation of trouble

(1) Wheel check

(2) Brake pedal check
(3) Brake fluid check
(4) Air pressure check

2. Riding Comfort
1) Outline
Brake pull

Left-and right-side braking action is unbalanced

Braking force(kg)

Lock

Left wheel
Right wheel
Angle of depressed pedal

Brake unit

2) Trouble Causes Chart

Use conditions

Entry of foreign substance in

gap between drum and lining
Faulty drum degree of roundness
Excessive drum wear

Left-and right-side difference

in vehicle weight

Rusted or damaged drum

sliding surface
Faulty brake shoe operation

Severe use of brakes

Road conditions

Faulty wheel cylinder and

piston operation
Broken or damaged return spring
Faulty drum and lining gap

Unequal air pressure

Air pipe clogging

Unequal wear
Uneven tread pattern
Tires

Faulty lining contact

Lining damage

Oil pipe clogging

Piping

Lining friction coefficient

disparity
Brake unit (lining)

Brake pull

Brake shoe deformation

3) Causes of trouble
(1) Faulty lining contact

Edge contact

Faulty

Center contact

Normal

(2) Lining damage

450
500C

(3) Lining friction coefficient disparity

()

Temperature(C)
Over-Recovery

(4) Faulty brake shoe operation

Wheel cylinder
Return spring

Brake lining

Brake shoe

(5)Rusted or damaged drum sliding face

Thermal crack
(6)Excessive drum wear

Heat spot

Scoring

4) Use conditions
(1) Left-and right-side difference in vehicle weight
Left-and right-side difference in vehicle weight

Brake pull
Heavy wheel weight

Lock

(2) Severe use of brakes

Excessive use of brakes
Brake fade

Friction heat

Difference in value between the left-and right-side linings

Brake pull

Brake fade

Vapor lock

Boiling point (C)

< Reference >

250

200
(Effect of DOT-3-equivalent brake fluid)
150

7
8
9 10
Water content (%)

Brake Fluid Water Content and Boiling Point

5) Grasping and confirming trouble phenomena

(1)Driving conditions
(2)Braking conditions
(3)Load conditions
(4)Frequency of occurrence
(5)Other

3. Faulty Braking
1) Trouble phenomena

Big pedal stroke

2) Trouble Causes Chart

Use conditions
Overloading

Control valve
Faulty brake valve
function

Air system freeze-up

Faulty pressure regulator

function

Faulty brake booster

function

Faulty air compressor

function

Fade

Severe use of brakes

Faulty relay valve

function

Causes peculiar to
vacuum servo brake

Brake unit

Air leak
Plugged (crushed) air pipe

Faulty braking

Vapor lock

Air replenishment and air piping

Brake fluid-related causes

Large gap between drum

and lining

Large master cylinder push

rod play

Using brake past lining use

limit

Faulty master cylinder cap

Faulty lining contact

Faulty hydromaster

Using lining with low friction

coefficient

Clogged air cleaner

Faulty vacuum check
valve
Crushed or damaged
vacuum hose pipe
Faulty vacuum pump
Vacuum system leakage
Faulty sliding of safety
cylinder piston

Overheated lining
Soiled lining surface; presence
of foreign substance
Excessively smooth lining
surface
Excessively smooth drum
sliding surface
Rough drum sliding surface

Causes peculiar to
vacuum servo brake

Brake unit

Insufficient brake
fluid quantity
Fluid leak from
pipe hose
Fluid leak from
wheel cylinder
Entry of air into
fluid pressure
system
Brake booster
interior fluid
leak

Brake fluid-related causes

Faulty braking

Insufficient pedal height

3) Causes of trouble
(1) Air system
[Air compressor]
0

8.5kg/cm
Idling : about 10 minutes
Full speed : about 3 minutes

[Pressure regulator]
7.0

8.5kg/cm

[Air leak]
Regular supply
After operation

Brake fluid piping

(2) Hydraulic system

[Oil leakage from piping]
Brake air piping

Brake fluid piping

[Faulty piston cup]

Damaged or cracked cup lip or base.
Rusted or damaged cylinder wall
Swollen or contracted cup
Invasion of foreign substance

piston

Piston cup

[Air entry]
Air suction from the wheel cylinder
Master cylinder secondary cup deterioration
Bubbles produced by vapor lock
Incomplete air bleeding work

(3) Control valve-related causes

[Brake booster function]

Characte
-ristics

Booster reference
parts number

44640-1211

0.40.15

1577

Must be 0

44640-1242

0.40.15

1577

At least 600

44640-1261

0.60.15

1537

At least 600

44640-1291

0.60.15

1537

Must be 0

Initial pressure (kg/cm) Fluid pressure (kg/cm)

Residual
pressure(mmHg)

Fluid pressure (kg/cm)

157
153

0.4
0.6

7
7

0.15
0.15

7
Relay valve signal pressure (kg/cm)

Brake booster Characteristics Diagram

(Tank pressure: 7kg/cm)

24
18
15

1. 5

1. 5

0.4

1
0

5.4

0.3

3.4

0.15

0.2

Brake valve outlet pressure(kg/cm)

[Brake valve function]

5
1

10

15

20

Angle of depressed pedal()

Operating Characteristics Diagram

(4) Wheel unit

Large gap between lining and drum
Faulty lining contact
Overheated lining
Soiled lining surface; presence of foreign substance
Excessively smooth lining surface
Excessively smooth drum sliding surface
Rough drum sliding surface

Center contact

(5) Use conditions

Braking force (F)

Friction Coefficient ()

[Overloading]

Pressurizing force (P)

4. Premature Brake Lining Wear

1) Outline
Vehicle's initial
braking velocity

Basic causes
of lining wear

G.V.W.

Frequent use
of brakes

2) Trouble Causes Chart

Premature wear on all wheels

Little play in master

cylinder servo brakes

Causes other
than brake drag

Unsuitable lining material

Swelling of master
cylinder piston cup
Faulty master cylinder
piston return
Faulty hydromaster
return
Faulty safety cylinder
piston return

Faulty brake cooling

Brake drag

Faulty brake pedal play

Faulty brake valve return

Foreign substance on
friction surface
Excessive use of brakes
Excessive use of brakes
at high speeds
Overloading

Faulty relay valve return

Faulty brake booster
return

Premature Brake Lining Wear

Causes peculiar to vacuum

servo brakes

Drum sliding surface roughness

Wheel bearing play
Excessive drum wear
Different materials used
between axles

Fault brake shoe return

Faulty wheel cylinder piston
return
Bent or damaged brake shoe
return spring
Eccentric drum

Causes other
than brake drag

Brake drag

Premature wear on
specific wheel(s)

Premature Brake Lining Wear

Reduced drum/lining gap

3) Causes of trouble
Premature Brake
Lining Wear

Use conditions
of the brakes

Wear rate(cm/kgm)

x10 -7 14
12

1.Lining temperature

10

2.

4.

3.
5.

6
4
2
100

200

Temperature (C)

300

4) Premature wear on all wheels due to brake drag

(1) Faulty brake pedal free play

Pedal height

(2)Faulty brake valve return

Pedal angle

(3) Faulty brake booster return

Faulty sliding of air piston and air cylinder
Bent or damaged air piston return spring
Faulty sliding of oil piston and cylinder
Faulty check valve functioning
(4) Faulty check valve functioning

Air piston

Oil piston

Check valve

Return spring

5) Premature wear on all wheels due to cause other than brake drag
(1) Unsuitable lining material

Grabbing

Wear

(2) Foreign substance on friction surface

(3) Excessive use of brakes at high speeds

1 W
Kinetic energy = V 2
2 g
W = Gross vehicle weight
V = Vehicle speed
g = acceleration of gravity (9.8mm/sec)

Wear volume

x10 -3

10.0
5.0
1.0
0.5

30

50

70
90
Initial speed(km/H)

Wear volume

(4) Overloading

Increasing of
lining temperature

Load

(5) Premature wear on specific wheels

Reduced drum/lining gap
Wheel bearing play
Fault brake shoe return
Brake drag
Faulty wheel cylinder piston return
Bent or damaged brake shoe return spring
Eccentric drum

Drum sliding surface roughness

Causes other
than brake drag

Excessive drum wear

Different materials used between axles

5. Brake Judder
1) Trouble phenomena

Abnormal vibration

2) Trouble Causes Chart

Drum rubout factors

Disk wheel

Foreign substance on hub

installation face
Excessively tightened hub nut

Hub bearing play

Suspension system resonance

Eccentric drum
Faulty installation on hub
Foreign substance on hub
installation face
Faulty hub installation face flatness

Faulty contact
Large friction coefficient

Other causes

Lining

Amplification factors

High-speed brake judder

Faulty hub installation face flatness

Drum

3) Mechanism by which high-speed judder occurs

Drum sliding face rubout

Fluctuating brake torque is produced
Brake vibration resonates in tire
rotating direction and is amplified
Vibration is transmitted to the cab

4) Confirming extent of judder

(1) Speed
(2) Cold or warm
(3) Steering or Cab
(4) laden or at normal times
(5) Front or Rear

5) Causes of trouble
High-Speed brake judder
1. Vibration of the front drum sliding faces
2.
3.
4.
5.

Vibration of the front drum sliding faces

Medium-duty vehicle
Heavy-duty vehicle

less than 0.1mm

0.15 mm

[Measuring drum runout]

Lining wear inspection hole

Magnet stand

Lining

Sliding face : about 2mm

[Causes of drum runout]

[1] Faulty disk wheel, drum, or hub installation face
[2] Excessively tightened hub nut
[3] Faulty installation on hub
Matching face

Improved flatness accuracy

5) Drum runout measuring procedure and measures

[1] Measure drum runout

5) Drum runout measuring procedure and measures

or
[1] Measure drum runout 0.1
less
Greater than 0.1

Replace with a low lining

5) Drum runout measuring procedure and measures

or
[1] Measure drum runout 0.1
less

Replace with a low lining

Greater than 0.1

[2] Measure disk wheel rubout

30 35mm

20 25mm
Without tire

With tire

5) Drum runout measuring procedure and measures

or
[1] Measure drum runout 0.1
less

Replace with a low lining

Greater than 0.1

or
[2] Measure disk wheel rubout 0.1
less

Check disk wheel installation face

30 35mm

20 25mm
Without tire

With tire

5) Drum runout measuring procedure and measures

or
[1] Measure drum runout 0.1
less

Replace with a low lining

Greater than 0.1

or
[2] Measure disk wheel rubout 0.1
less
Greater than 0.1

Check disk wheel installation face

Normal

Abnormal
Repair

Install a high-accuracy disk wheel

5) Drum runout measuring procedure and measures

or
[1] Measure drum runout 0.1
less

Replace with a low lining

Greater than 0.1

or
[2] Measure disk wheel rubout 0.1
less
Greater than 0.1

Check disk wheel installation face

Normal

Abnormal
Repair

Install a high-accuracy disk wheel

[3] Repair the hub and drum assembly rubout

5) Drum runout measuring procedure and measures

or
[1] Measure drum runout 0.1
less

Replace with a low lining

Greater than 0.1

or
[2] Measure disk wheel rubout 0.1
less
Greater than 0.1

Check disk wheel installation face

Normal

Abnormal
Repair

Install a high-accuracy disk wheel

[3] Repair the hub and drum assembly rubout

Change the hub

and drum phase

5) Drum runout measuring procedure and measures

or
[1] Measure drum runout 0.1
less

Replace with a low lining

Greater than 0.1

or
[2] Measure disk wheel rubout 0.1
less
Greater than 0.1

Check disk wheel installation face

Normal

Abnormal
Repair

Install a high-accuracy disk wheel

[3] Repair the hub and drum assembly rubout

Change the hub

and drum phase
Cannot be adjusted

[3] Repair the hub and drum assembly rubout

Change the hub

and drum phase
Cannot be adjusted
Grind the drum sliding faces
with the hub and drum
assembled or with the hub,
drum, and disk wheel
assembled

[3] Repair the hub and drum assembly rubout

Change the hub

and drum phase
Cannot be adjusted
Grind the drum sliding faces
with the hub and drum
assembled or with the hub,
drum, and disk wheel
assembled

[4] Measure the disk wheel assembly rubout

Change the hub

and drum phase

[3] Repair the hub and drum assembly rubout

Cannot be adjusted
Grind the drum sliding faces
with the hub and drum
assembled or with the hub,
drum, and disk wheel
assembled
or
[4] Measure the disk wheel assembly rubout 0.1
less
Greater than 0.1

Test drive

Change the hub

and drum phase

[3] Repair the hub and drum assembly rubout

Cannot be adjusted
Grind the drum sliding faces
with the hub and drum
assembled or with the hub,
drum, and disk wheel
assembled
or
[4] Measure the disk wheel assembly rubout 0.1
less

Test drive

Greater than 0.1

Replace with a high-accuracy disk wheel

Change the hub

and drum phase

[3] Repair the hub and drum assembly rubout

Cannot be adjusted
Grind the drum sliding faces
with the hub and drum
assembled or with the hub,
drum, and disk wheel
assembled
or
[4] Measure the disk wheel assembly rubout 0.1
less

Test drive

Greater than 0.1

Replace with a high-accuracy disk wheel
Unsatisfied

Change the hub

and drum phase

[3] Repair the hub and drum assembly rubout

Cannot be adjusted
Grind the drum sliding faces
with the hub and drum
assembled or with the hub,
drum, and disk wheel
assembled
or
[4] Measure the disk wheel assembly rubout 0.1
less

Test drive

Greater than 0.1

Replace with a high-accuracy disk wheel
Unsatisfied

Replace the lining with a low lining