Slide 1: Brake System Fundamentals
Slide 2: Typical System (No ABS)
Slide 3: Typical Layout of System (with ABS)
Slide 4: Brake Pedal Design Advantage by Leverage  First Mechanical Advantage is Driver’s foot  Length of Lever determines force applied  Uses Fulcrum  Pedal Ratio 10 2 5:1
Slide 5: Advantage by Hydraulics
Slide 6: Components
Slide 7: Drum Brake System
Slide 8: Disc Brake Caliper Assembly
Slide 9: Sliding Caliper  Applies pressure to two pads on opposite sides of rotor  Caliper   Sliding Fixed  Friction Material exposed to air
Slide 10: Fixed Caliper  Applies two pistons to opposite sides of rotor  Caliper stays stationary  Disc Brakes require higher hydraulic pressure
Slide 11: Master Cylinder
Slide 12: Brake Plumbing  Rigid steel brake lines are double wall  Flexible hoses connect rigid lines on vehicle to each wheel  Transmits hydraulic fluid to each wheel
Slide 13: Pressure Control Valves All systems use one or more valves
Slide 14: Wheel Cylinder  Wheel cylinder or caliper pistons are “slave cylinders”  Change hydraulic pressure back into mechanical force  Can use one or two cylinders at each wheel
Slide 15: Power Assist Increases force of driver’s foot
Slide 16: Cable Parking Brake Parking or “Emergency” Brake
Slide 17: Parking Brake Systems  Foot or Hand Brake  Are cable controlled  Several Styles    As shown Drum in hat Driveline
Slide 18: Brake Legal & Health Issues  Federal Motor Vehicle Safety Standards (FMVSS)  FMVSS 105 – requirements for hydraulic service brakes and associated parking brakes.  Brake test Pg. 20
Slide 19: Brake Repair and the Law  Technician is always liable for damage or injuries resulting from repairs performed in an unprofessional or unworkmanlike manner.  Restore the system and components so they perform to original specifications.
Slide 20: Brakes and Health  Asbestos exposure – individual asbestos fibers from brake or clutch disc linings go airborne and then inhaled into the lungs.  Asbestosis – progressive and disabling lung disease that is irreversible once scaring begins. Deadly!
Slide 21: Precautions  Brake vacuum  Wet brake cleaning (Brake Buggy)  Brake clean  Personal Cleanliness  Clean hands  Don’t smoke  Wash clothes separately
Slide 22: Chemical Poisoning  Brake cleaning Chemicals  Follow directions  Read Material Safety Data Sheets (MSDS)  If you are working in an unsafe environment:  Talk to your employer  Talk to OSHA
Slide 23: BRAKE TOOLS AND EQUIPMENT