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