Brake system 1
Copyright by Kia Motors Corp. All rights reserved.
Brake system 1 2
Introduction
Brake system 1 3
Operating principle
Hydraulic Force Multiplication
Leverage
Hydraulic Force Multiplication
100N
Brake applied 900N
apply force (50N)
Brake system 1 4
Typical layout of a hydraulic brake system
Brake Fluid Reservoir Brake booster
Master Cylinder Brake cylinder
Brake pedal
Proportioning valve
ABS/TCS/ESP Brake lines
HECU
Brake caliper and pad
Brake disc Brake drum and shoe
Brake system 1 5
Classification
Intended Purpose
Service brake system Secondary brake system Parking brake system
Operating Principle
Muscular energy Power assisted
Power brake system
brake systems brake systems
Construction
Single circuit brake system Double circuit brake system
Brake system 1 6
Brake pedal
Member assembly bracket
Brake switch
Return spring
Bolt
Brake switch adjustment
Lower pedal
Brake pedal and lever
Raise pedal
Pedal height adjustment
Brake system 1 7
Master cylinder
Secondary brake fluid reservoir
Primary brake fluid reservoir
Float switch
Secondary piston
Primary piston
from Brake normal braking
Booster
Spring
Primary brake circuit
Proportioning Valve (only on Conventional Brake System)
Secondary brake circuit
Brake Fluid Warning Light Checking procedure leakage in primary brake circuit
Brake system 1 8
Brake fluid
°C
Boiling temperature
300 Reference standard for testing FMVSS 116 SAE J 1703
Requirements / Date DOT3 DOT4 DOT5 11.83
250
Dry boiling point at least °C 205 230 260 205
200
Wet boiling point at least °C 140 155 180 140
150 Cold viscosity at -40°C mm²/s 1500 1800 900 1800
100
0 1 2.2 3.2 4 5
Water components weight %
Note:
Brake fluid can absorb moisture through the system's hoses, mostly by diffusion. This is the main
reason why the brake fluid should be replaced every 1......2 years. This brake fluid change is vital
for maintaining braking safety. During this operation, particular attention should be devoted to
expelling any air trapped in the system (air bleeding).
Brake system 1 9
Brake circuit layouts
Single brake circuit Double brake circuit, Front / Rear diagonal split
The Air Bleeding procedure for each
brake circuit layout is different!
Double brake circuit, Front / Rear split
Brake system 1 10
l
Brake circuit, service procedures
B
u a
Master cylinder to brake line A
an
Brake Line to
brake hose
Brake line to brake
hose
p M C
h o
Brake hose
s
to caliper
rk A
B
W o C
o m Proportioning
r
valve Air bleed screw D
e f C
p l Brake hose to caliper or
am Brake line to wheel cylinder
S D B A
Brake system 1 11
Pressure regulating valve
2 1
Rear – axle brake pressure
5
1 3
4 a 6
2
b 3
4 5
6
Front - axle brake pressure
1 From tandem master cylinder
2 To the wheel brakes 1 Unreduced pressure
3 Mechanical linkage 2 Ideal pressure curve (laden vehicle)
4 Control springs 3 Reduced pressure (laden vehicle)
5 Stepped piston 4 Ideal pressure curve (unladen vehicle)
a Laden vehicle 5 Reduced pressure (unladen vehicle)
b Unladen vehicle 6 Switching point
Brake system 1 12
Drum brake
Brake cylinder
Pistons
Brake released
Brake drum
Bowdencable
Handbrake
Backing plate
Handbrake
Figure #1
mechanism
Adjuster
mechanism
Brake shoe and pad
Figure #2
Brake system 1 13
Self adjusting and parking brake mechanism
Brake released Brake applied #1 Brake applied #2 Brake released
Parking brake released Parking brake applied Brake lever adjustment screw
Brake system 1 14
Drum brake, service procedure
Brake shoe
Thickness check Brake drum diameter check
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous
to your health! Never use an air hose or brush to clean the brake!
Brake system 1 15
Caliper disc brake
Support
Floating caliper housing
Piston
Brake pad
Brake disc
Released position Apply position
Floating type
Fixed caliper
Piston
Brake pad
Brake disc
Brake Pad check Special Service Tool
Fixed type
Brake system 1 16
Brake disc
Cooling channel
Internally vented Brake Disc thicknes check
Solid Brake Disc Brake Disc Run Out check
Brake system 1 17
Braking process
in m/s²
0
Reaction time Response time Braking duration t in s
Stopping time
Reaction Response
Braking Distance
Distance Distance
Stopping distance
Brake system 1 18
Brake booster
Brake fluid reservoir
To Master Cylinder
Vacuum chamber
Atmospheric pressure
Brake booster
Brake lines Brake pedal
To Master Cylinder
Vacuum chamber
Tandem Type Single Type 2-Ratio Type Atmospheric pressure
Brake system 1 19
Brake booster, service procedures
Check Valve testing Vacuum switch (only Diesel) Before installation
Vacuum hose
Check valve
Vacuum source Warning Light
Checking the Vacuum Brake Booster
When engine When engine Good Not good
Good Not good
is stopped is started
1st
2nd
3rd
Brake system 1 20
Brake booster
Diaphragm
Working piston
Reaction disc
Filter
Vacuum chamber
Output rod
Input rod
Valve body
Working chamber
Brake system 1 21
Valve body (released position)
Vacuum port is open
Atmospheric port is closed
Intake manifold vacuum is present on
both sides of the piston.
Vacuum
Atmospheric Pressure
Brake system 1 22
Valve body (apply position)
Vacuum port is closed
Atmospheric port is open
Atmospheric pressure pushes the piston
forward, applying the brakes.
Vacuum
Atmospheric Pressure
