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Section 4 Brake System

The document discusses the brake system of a vehicle. It describes the structure and function of the service brake system and parking brake system. It provides specifications for braking pressure, brake fluid, and the parking brake. It also describes the brake pedal, piping, installation of the brakes, and the structure and maintenance of the brake master cylinder.

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André Targino
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68 views5 pages

Section 4 Brake System

The document discusses the brake system of a vehicle. It describes the structure and function of the service brake system and parking brake system. It provides specifications for braking pressure, brake fluid, and the parking brake. It also describes the brake pedal, piping, installation of the brakes, and the structure and maintenance of the brake master cylinder.

Uploaded by

André Targino
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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SECTION 4 BRAKE SYSTEM

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1


Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
SECTION 4 BRAKE SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
There are two brake systems, the service brake system and the parking brake system.
In the service brake system, oil pressure is generated in the master cylinder by treading on the brake
pedal. This pressure causes the brake lever to press the pressure pin which gives braking pressure to
the disk carrier.
In the parking brake system, the brake lever is operated by cable. Therefore the pressure pin makes
braking pressure onto the disk carrier.

2. SPECIFICATION
1) BRAKE
Item Criteria Unit Specification

Braking pressure ÂIn operation bar/psi 58-80/725-1161


ÂNominal(max const) bar/psi 60/870
ÂLimit(peaks) bar/psi 90/1305
Brake fluid DOT3, DOT4
Volume in the ÂIn operation cm3/cu.in. 7/0.43
brake cylinder ÂUpon max wear cm /cu.in.
3
14/0.85

2) PARKING BRAKE

Item Specification

Type Ratchet, internal expanding mechanical type


Parking lever stroke(Drive unit) 13mm(Initial condition)
Parking cable stroke(Parking lever) 28mm(Initial condition)

4-1
3. BRAKE PEDAL AND PIPING

Drive unit(RH)

Drive unit(LH)
35B7BS01

1 Brake pedal & bracket assy 3 Reservoir tank assy


2 Parking lever assy 4 Brake master cylinder

4-2
4. BRAKE INSTALLATION

Service brake connection


Parking brake
Service brake bleeder nipple

35B7BS10

1) The brakes chamber shares the reduction gear oil and it is continuously feeded during the working
processing. During the installation of the reduction gear, it is necessary to verify that the
handbrake's draught cable is not under tension and that the gap between the brake disks is not
reduced: this would compromise the correct working of the brake.
2) It is necessary to check every 2000 working hours that the stroke of the brake piston is not over 3.5
mm, otherwise it is necessary to replace the brake disk. In order to estimate the worn of the discs,
disconnect the brake rod. Move the lever closer the brake piston, then pull it strongly and measure
the stroke of the lever: it has not to be over 21mm. In case the stroke exceed this value, it's required
to replace the disc pack.
3) The M10x1 plug is used as connection to the hydraulic service brake circuit.
4) The bleeder nipple located in the opposite side of the service brake connection is used for bleeding
the braking circuit before it is started.

4-3
5. BRAKE MASTER CYLINDER
1) STRUCTURE

18 1 3 16 17 2 14 15 19 5 6 9

4 20 12 13 8 7 10 11

35B7BS09

1 Body 6 Head 11 Snap pin 16 Air bleeder


2 Spring(Large) 7 Head pin 12 Stop ring 17 Cap
3 Check valve 8 Boot nut 13 Boot 18 Cap
4 Valve seat 9 Pin 14 Retainer 19 Cap
5 Rod 10 Washer 15 Nipple 20 Piston kit

2) DISASSEMBLY
(1) Remove the master cylinder boot(13) and remove the rod(5).
(2) Remove the stop ring(12) and take out the piston kit(20) and spring(2).
(3) Specification of master cylinder.
ÂCylinder bore diameter : 19.05/28.57mm
ÂPiston stroke : 25mm
3) INSPECTION
(1) Clean and check these components.
ö Use isopropyl alcohol or brake fluid for washing the components. Do not use gasoline, kerosene or any
other mineral oils. When using alcohol, do not leave rubber parts in the liquid for more than 30 seconds.
(2) Inspect the inside wall of the master cylinder, and if any faults are found, replace the cylinder assembly.
(3) Replace the boot(8), piston kit(20), if deformation or any other defect is found.
4) ASSEMBLY
ö Prior to assembly make sure again of no contaminant of the components. Apply a thin coat of
brake oil to the components.
ÂAssembly is in opposite order to disassembly.

4-4

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