Руководство по эксплуатации Toyota - Системы торможения (EN)

BRAKE SYSTEMS Course 553 Technician Handbook © 2013 Toyota Motor Sales, U.S.A., Inc. TOYOTA Technical Training All rights reserved. This book may not be reproduced or copied, in whole or in part by any means, without the written permission of Toyota Motor Sales, U.S.A., Inc. Revision Date: February 28, 2013

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Table of Contents 553 Brake Systems Brake Systems Course Introduction .............................................................................. 2 Section 1: Fundamentals Section 1 Topics ................................................................................... 3 Energy Conversion ............................................................................... 4 Hydraulics ............................................................................................. 5 Brake Systems ..................................................................................... 6 Brake Fade ...........................................................................................

7 Brake Fluid ........................................................................................... 8 Section 2: Master Cylinder Section 2 Topics ................................................................................... 9 Master Cylinder .................................................................................. 10 Master Cylinder Components ............................................................. 11 Brake Application ................................................................................ 12 Brake Release ....................................................................................

13 Fluid Return ........................................................................................ 14 Piston Leakage ................................................................................... 15 Portless Master Cylinder .................................................................... 16 Brake Fluid Level Warning Light Switch ............................................. 17 Brake Warning Light Circuit ................................................................ 18 Piping Design ..................................................................................... 19 Conventional Split ...............................................................................

19 Diagonal Split ..................................................................................... 19 Brake Tubing ...................................................................................... 20 Master Cylinder Bleeding ................................................................... 21 Brake System Bleeding ...................................................................... 22 Section 3: Disc Brakes Section 3 Topics ................................................................................. 23 Disc Brakes ........................................................................................

24 Floating Caliper .................................................................................. 25 Fixed Caliper ...................................................................................... 26 Self-adjusting Mechanism .................................................................. 27 Brake Pad Assembly .......................................................................... 28 Caliper Slide, Pad & Shim .................................................................. 29 Pad Wear Indicator ............................................................................. 30 Disc Rotor ...........................................................................................

32 Rotor Parallelism ................................................................................ 33 Rotor Run-Out .................................................................................... 34 Causes of Rotor Run-Out ................................................................... 34 Measuring Rotor Run-Out .................................................................. 34 Indexing Rotors .................................................................................. 34 On-Car Brake Lathe ........................................................................... 35 Lug Nut Tightening Procedure ............................................................

36 Technical Training i

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Table of Contents 553 Brake Systems Section 4 Topics ................................................................................. 39 Drum Brakes ....................................................................................... 40 Wheel Cylinder ................................................................................... 41 Brake Shoes and Linings .................................................................... 42 Brake Drum ........................................................................................ 43 Leading/Trailing ..................................................................................

44 Dual-Servo .......................................................................................... 45 Dual Mode .......................................................................................... 46 Self Adjusting Brake Shoes ................................................................ 47 Drum Brake Lubrication ...................................................................... 48 Drum Brake Inspection ....................................................................... 49 Brake Shoe Adjustment ...................................................................... 50 Brake Adjustment Caliper ...................................................................

51 Section 5: Parking Brake Section 4: Drum Brakes Section 5 Topics ................................................................................. 53 Parking Brake ..................................................................................... 54 Linkage Components .......................................................................... 55 Drum Parking Brake Components ....................................................... 56 Leading/Trailing Parking Brake Adjustment ....................................... 57 Exclusive Type Disc Parking Brake .....................................................

58 Caliper Assembly Disc Parking Brake ................................................ 59 Caliper Assembly Parking Brake Automatic Adjustment .................... 60 Resetting the Caliper Assembly Disc Parking Brake Piston ............... 61 Section 6: Brake Diagnosis Section 6 Topics ................................................................................. 63 The 6-Step Diagnostic Process .......................................................... 64 Verify the Concern .............................................................................. 65 Preliminary Inspection ........................................................................

65 Identify All Symptoms ......................................................................... 66 Pedal Feel Symptoms ........................................................................ 67 Brake Pedal Position .......................................................................... 68 Pedal Height ....................................................................................... 68 Free-Play ............................................................................................ 68 Reserve Distance ...............................................................................

68 Stop Light Switch ................................................................................ 68 Brake Pedal Reserve Adjustment ....................................................... 69 Stop Light Switch Adjustment ............................................................. 70 Brake Pull Symptoms ......................................................................... 71 Noise Symptoms ................................................................................ 72 Vibration Symptoms ........................................................................... 73 Find the Cause ...................................................................................

74 Repair and Confirm ............................................................................ 75 ii Technical Training

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Table of Contents 553 Brake Systems Section 7: Brake Booster Section 7 Topics ................................................................................. 77 Brake Booster ..................................................................................... 78 Booster Operation .............................................................................. 79 Control Valve Closed .......................................................................... 79 Control Valve Open ............................................................................ 79 Booster Air Valve – Brakes Not Applied .............................................

80 Booster Air Valve – Brakes Applied (Vacuum Valve Closed) .............. 81 Booster Air Valve – Brakes Applied (Air Valve Open) ........................ 82 Booster Air Valve – Release Position ................................................. 83 Booster Air Valve – No Vacuum ......................................................... 84 Tandem Brake Booster – Brakes Released ....................................... 85 Tandem Brake Booster – Brakes Applied .......................................... 86 Brake Pressure Conversion Unit ........................................................ 87 Normal Vacuum Operation .................................................................

88 Loss of Vacuum or High Brake Force .................................................. 89 Booster Diagnosis – Operating Check ............................................... 90 Air Tightness Check ........................................................................... 91 Air Tightness Check Under Load ........................................................ 92 Booster Push Rod Gauge .................................................................... 93 Master Cylinder Precautions .............................................................. 94 Mechanical BA Construction ..............................................................

95 Mechanical BA Operation ................................................................... 96 Active Brake Booster .......................................................................... 97 Active Brake Booster – Braking .......................................................... 98 Hydraulic Brake Booster ................................................................... 100 Power Supply Section ...................................................................... 101 Master Cylinder and Brake Booster Construction and Operation ..... 102 Pressure Increase ............................................................................

103 Pressure Reduction ........................................................................... 104 Power Supply Malfunction ................................................................. 105 Front Brake Malfunction .................................................................... 106 Hydraulic Brake Booster Service and Precautions ............................ 107 Master Cylinder Solenoid Bleeding ................................................... 108 Section 8: Hydraulic Brake-force Distribution Section 8 Topics ................................................................................

109 Hydraulic Control ............................................................................... 110 Proportioning Valve Location ............................................................. 111 Hydraulic Pressure Curve .................................................................. 111 Proportioning Valve ........................................................................... 112 Double Proportioning Valve FWD ...................................................... 113 Load Sensing Proportioning Valve (LSPV) ........................................ 114 Proportioning Valve in Unloaded Position .........................................

115 Load Sensing Proportioning and Bypass Valve (LSPBV) ................. 116 Fail-safe Operation ............................................................................ 117 Pressure Gauge SST ......................................................................... 118 LSPV Adjustment .............................................................................. 119 Technical Training iii

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