BRAKE SYSTEM

function:
Reduce speed and stop the vehicle.
Allows parking in a declining
As a means of ensuring safety and safe driving
BRAKE SYSTEM
COMPONENTS - COMPONENT SYSTEM REM
PRINCIPLE REM
REM SYSTEMS BASIC PRINCIPLES
Changing the energy of motion into heat energy. Generally brake system work
caused by the combination of suppression against the rotary motion systems.
Braking effect is obtained from the friction generated between the two objects
TYPE - TYPE REM
Brakes are used on motor vehicles can be classified into several types depending
on usage
~ Foot brake (foot brake), using the feet to control the operation of
speed and stop the vehicle
~ Parking Brake (Parking brake) to hold the vehicle so that is not easy
moving at the time of parking
~ Brakes additional (auxiliary brake) to help brake the foot, generally used
on large vehicles and heavy
footbrake
GROUPED INTO 2

Hydrolis (Hydraulic Brake),

Its construction is simpler but more responsive

Pneumatically (Pneumatic Brake)

Construction is complicated, because they have to use a
compressor to produce pressurized air
BASIC PRINCIPLES OF BRAKE WORKING

By law pascal:
Pressure liquid is passed to all directions with equal pressure

The pressure generated by the

master cylinder and forwarded to
the pipe - the pipe line and the
wheel cylinder
BRAKE PEDAL TO WORK
Based on the principle of the lever that
changes the style of a small pedal
pressure to be great

A - Distance the pedal to the fulcrum

B - Distance pushrod to fulcrum
F1 - style presses the pedal
F2 - style pushrod
MASTER CYLINDER TYPE AND CONSTRUCTION
There are two types of master cylinders
~ Single
~ Double (tandem)
HOW TO WORK

When the brake pedal is stepped on

Piston cup located between the inlet port
and compensating port. So there are two
channels between the cylinders and tanks
resevoir

When the brake pedal is stepped on

The piston moves to the right and close the
compensating piston cup port, so causing
the pressure inside the cylinder hydrolis
increases and the pressure is transmitted
to the wheel cylinder
WHEEL CYLINDER

There are two kinds of wheel cylinder

~ With a piston to push the brake shoe
~ With two piston to push the brake shoe
Brake shoe and lining

Brake shoe
Steel plate material

Brakes canvas
Materials, Mixture of metallic fiber,
brass, lead, plastic, etc.
How to install the brake shoe rivet or
the manner in glue
 DRUM BRAKE

Drum brake components: Note:

backing plate When the brake linning respectively rub
wheel cylinder against the brake drum, the heat generated
Brake shoe & linning respectively can reach 200 ~ 300oC
Brake drum
DRUM BRAKE TYPES:
LEADING AND TRAILING

One wheel cylinder with two pistons that push the brake shoe to hit the top of
the drum

Note:
At the leading shoe out faster than the
trailing shoe
TWO LEADING

This type has two of each wheel cylinder -

each has a single piston

advantages:
At the time the vehicle moves forward both
brake shoes, a leading thus becoming more
standard brakes
TIPE DUAL TWO LEADING

This type has two of each wheel cylinder -

each has two pistons
Effects that occur very good braking when
the vehicle forward or backward
UNI - SERVO

This type has one wheel cylinder with a

piston and the
Adjusting the cylinder can move freely.

advantages:
When the second advanced vehicle brake shoes
become the leading

The disadvantages:
When both vehicles back into the trailing brake
shoe
DUO - SERVO

This type is a refinement of the Union type servo

So this type using a single brake wheel cylinder with
two pistons and adjusting cylinder that can move
freely.
So that when the vehicle is moving forward or
backward serves both as a leading shoe brake shoe
ANCHOR PIN

This type has one wheel cylinder with two

pistons Brake shoe bottom fastened using
a pin

f done braking conditions are like in the picture

(arrow direction), then the primary shoe will work as
a leading secondary shoe and trailing shoe will
work as
BRAKE SHOE CLEARANCE

Gap handling can cause:

~ If it's too large will cause a delay in braking
~ If too small, the brakes will be jammed
~ If it is not the same would cause vehicles attracted toward unity
CLEARANCE SETTER AUTOMATIC BRAKE SHOE
HOW TO WORK
When the parking brake works, then the lever is attracted to the left. At the same time,
the tuner will lever rotates clockwise around the pin of the brake shoes mounted,
rotating the adjusting screw

By the time the gap reaches the standard price (slit drum brake shoes with + / -
0.5 mm, then the adjusting lever gerberak only slightly (can not hook gear
adjusting screw). So the brake shoe gap remains.
DISC BRAKE

Disc brakes (disc brakes) consists of:

Disc (rotor disc)
Disck Pad
caliper

Braking power is generated due to friction

between pad and disc rotor disc

advantages:
Better heat radiation
When exposed to water dry faster
Construction is simpler
Easy to care
losses:
Self small energinzing
Requires a large hydraulic pressure
TYPES OF DISC BRAKE
FIXED TYPE / DOUBLE PISTON

In this type of braking power obtained when the pad is pressed by hydraulic
pistons from both sides of the disc
FLOATING CALIPER TYPE

In this type there is only one piston. Hydraulic pressure from the master cylinder
push the piston (A) and then pressing the disc. At the same time pressing the
hydraulic pressure pad (B) cause the caliper to move to the right and clamped
discs and there was a braking
AUTO SETTER
Normal gap:
When the brake is operated, the piston
seals to form an elastic like the picture.
When the brake pedal is released, the
piston seals will return to its original
shape. And draw the piston back. The
amount of deformation of the seal
together with a gap pad against the
rotor kit
Gap is too large:
If we pad is worn out, when the brake is
operated then the movement of the piston
will go further, but the magnitude of
deformation of the seal remains. If the
pedal is released, the piston will return
with a distance equal to the deformation of
the slits seals and brakes have been set.
DISC BRAKE PAD
Material, a mixture of metallic fiber and iron
filings, the so-called semi-metallic disc
pads.
Gap in the disc brake, intended to show the
thickness limit of the allowable pad kit
Anti squel shim serves to prevent noise
when braking
ROTOR DISC
Cast iron materials
There are 3 kinds of rotor disc

Solid disc type

Ventilated disc type

Perforated hole at its center that serves as cooling to prevent
fading

Solid disc type with drum

Also serves as a drum for the parking brake
PARKING BRAKE
Divided into 2 types
~ Rear wheel typeTipe
~ centerTipe ( at output transmisi )

Cara kerja
Dengan menarik tuas rem parkir, maka rem bekerja melalui parking brake cable,
intermadiate lever, pull rod, equalizer, parking brake cable kiri dan kanan
TIPE – TIPE TUAS REM PARKIR

Lever type
Biasanya digunakan pada kendaraan penumpang dan kendaraan commercial
Stick type
Biasanya digunakan pada kendaraan commercial
Pedal type
Biasanya digunakan pada kendaraan penumpang dan kendaraan mewah
Cara membebaskannya menggunakan pedal
TIPE – TIPE REM PARKIR
SHARING
Tipe ini digabung dengan rem kaki. Hubungannya dilakukan secara mekanik dengan
sepatu rem atau pad rem

Kendaraan dengan rem tromol.

Pada tipe rem parkir ini, sepatu rem akan
mengembang oleh brake lever dan shoe
strut
TIPE – TIPE REM PARKIR
SHARING

Mekanisme rem parkir disatukan dalam

caliper rem
Gerakan tuas menyebabkan levershaft
berputar, dan mengakibatkan spindle
menggerakkan piston untuk mendorong
pad menjepit disc
TIPE – TIPE REM PARKIR
DEVOTED

Rem parkir tipe devoted, digunakan pada mobil yang menggunakan rem belakang model
cakram
Pada tipe ini cara kerjanya sama dengan tipe rem parkir tromol.
TIPE – TIPE REM PARKIR
CENTER BRAKE

Tipe ini banyak digunakan pada kendaraan komesial ( niaga )

Tipe ini adalah salah satu tipe rem parkir tipe tromol yang dipasangkan
diantara transmisi dan propeller shaft.
BRAKE BOOSTER

Fungsi :
Untuk melipat gandakan daya penekanan pedal, sehingga daya pengereman menjadi
lebih besar
BRAKE BOOSTER
PRINSIP KERJA BOOSTER REM
Bila vacuum bekerja pada kedua sisi piston, maka piston akan terdorong ke kanan oleh
pegas. Bila tekanan atmosfir masuk ke ruang A, maka piston bergerak ke kiri menekan pegas
karena adanya perbedaan tekanan, menyebabkan batang piston menekan piston master
silinder.
BRAKE BOOSTER
BRAKE BOOSTER
CARA KERJA KETIKA PEDAL BELUM DITEKAN

Air valve tertarik ke kanan

oleh air valve return
spring, bertemu dengan
kontrol valve sehingga
tertutup. Dan udara luar
tidak bisa masuk ke
variable pressure
chamber. Vacuum valve
terbuka menyebabkan
terjadinya kevacuuman
pada constant dan
variable pressure
chamber. Piston terdorong
ke kanan oleh pegas
diapragma
BRAKE BOOSTER
CARA KERJA KETIKA PEDAL DITEKAN

Valve operating rod

mendorong air valve
control valve,
menyebabkan
vacuum valve
tertutup dan air valve
terbuka hal ini
menyebabkan udara
luar masuk ke
variable pressure
chamber. Perbedaan
tekanan antara
variable dan
constant pressure
chamber
menyebabkan piston
bergerak ke kiri
KATUP PENYEIMBANG

Kendaraan yang mesinnya terletak didepan, bagian depannya lebih berat dibandingkan
dengan bagian belakangnya. Bila kendaraan di rem akan menyebabkan beban ban depan
bertambah dan beban ban belakang berkurang.
Bila daya cengkeram pengeremannya berlaku sama pada ke empat rodanya, maka roda
belakang yang memiliki beban lebih kecil cenderung akan mengunci lebih dulu sehingga
menyebabkan ngepot ( skid )
KATUP PENYEIMBANG

Dengan alasan beban berat kendaraan yang lebih berat pada bagian depan pada saat
terjadi pengereman, maka diperlukan proporsioning valve untuk mengurangi tekanan
hidraulis untuk silinder roda belakang, sehingga mencegah terjadinya terjadinya ngepot
Proporsioning valve ditempatkan pada pipa rem yang ke bagian belakang
JENIS – JENIS KATUP PENYEIMBANG ( PROPORSIONING VALVE )
PROPORTIONING AND BYPASS VALVE ( P & BV )
JENIS – JENIS KATUP PENYEIMBANG ( PROPORSIONING VALVE )
LOAD SENSING PROPORTIONING VALVE AND BYPASS VALVE ( LSPV & BV )
JENIS – JENIS KATUP PENYEIMBANG ( PROPORSIONING VALVE )
PROPORTIONING VALVE (P - VALVE )
PRINSIP KERJA PROPORSIONING VALVE
TEKANAN MASTER CYLINDER RENDAH
Tekanan hidraulis dari
master silinder
diteruskan dari ruang
“A“ ke ruang “B” melaui
katup “C”. Tekanan di
ruang “A” dan “B”
menjadi samasama.
Tetapi luas permukaan
piston di ruang “B” lebih
besar dari pada ruang
“A” , menyebabkan
piston bergerak ke kiri.
Gerakan ini berlawanan
dengan pegas yang
mendorong piston dan
menyerap gerakan
piston bila mencapai titik
dimana daya pegas
seimbang dengan
tekanan hidraulis.
PROPORSIONING VALVE
PRINSIP KERJA PROPORSIONING VALVE
TEKANAN MASTER CYLINDER TINGGI

Piston makin bergerak ke kiri sampai katup “C” menutup.

Pada saat ini terjadi Split Point
Bila tekanan hidraulis pada ruang “A” dinaikkan lagi, piston bergerak ke kanan dan
membuka katup “C”. Karena tekanan di ruang “B” bertamabah, piston bergerak ke kiri
karena perbedaan luas penampang dan matutup katup “C”.
Prosesini terjadi secara berulang –ulang untuk mengatur tekanan yang bekerja di wheel
cylinder belakang
PRINSIP KERJA P&B VALVE
TEKANAN MASTER CYLINDER RENDAH

Cara kerja saat tekanan master cylinder rendah pada blend valve sama dengan cara kerja
saat tekanan master cylinder rendah pada proportioning valve
PRINSIP KERJA P&B VALVE
TEKANAN MASTER CYLINDER SEDANG

Cara kerja saat tekanan master

cylinder sedang pada blend
valve sama dengan cara kerja
saat tekanan master cylinder
tinggi pada proportioning valve

TEKANAN MASTER CYLINDER TINGGI

Ssaat tekanan master cylinder tinggi, by
pass valve bekerja, dimana tekanan minyak
rem mendorong piston melawan tegangan
pegas. Seal tidak menutup saluran,
sehingga tekanan hidraulis di master
cylinder sama dengan wheel cylinder.
Pada blend proportioning valve terdapat
dua split point