PT.

 ALUN
Technical Dept.
Training Section

Brake system

Basic Training Chassis

 Brake system

Brake system contents :

● Air system

● Pneumatic diagram

● Air brake system controlled by electric (EBS)

● Anti--lock brake system

Anti y ((ABS))

● Z – cam brake mechanism

Basic Training Chassis

 Brake system

Air system
Air system T il
Trailer control
l
Relay
System design Protection
Reservoir Quick 
release
l
Filter & dryer

Production Chamber

Chamber
Parking 
g

Load 
sensing
i

Pilot

S
Suspension
i
Main brake
Basic Training Chassis
 Brake system

Air system
Air system
Supply energy                   
components & function  Max
Max.. the air supply pressure regulating ± 12 bar

 Min
Min.. air pressured for circuit brake tanks ± 8 bar

 Regeneration tank also required for fill the lack of air

1 pressure on circuit brake tanks when brake is applied

4
2

Basic Training Chassis

 Brake system

Air system
Air system
Pressure regulating methods

A B

The ESS compressor

The ESS compressor

Basic Training Chassis

 Brake system

Air system
Air system
A
Pressure regulating methods

The compressor with pressure regulator

Basic Training Chassis

 Brake system

Air system
Air system
Pressure regulating methods
B
A

The dryer with 
pressure regulator

Basic Training Chassis

 Brake system

Air system
Air system
Pressure regulating methods

The dryer with electrical 
system (APU)
system (APU)

Basic Training Chassis

 Brake system

Air system
Air system
Front wheel brake circuit

Basic Training Chassis

 Brake system

Air system
Air system
Rear wheel brake circuit

Basic Training Chassis

 Brake system

Air system
Air system
Parking brake circuit

Basic Training Chassis

 Brake system

Air system
Air system
Conversion energy activation 
Spring brake chamber

Brake chamber,
single diaphragm

A B

Basic Training Chassis

 Brake system

Pneumatic diagram
Pneumatic diagram
Color key for diagram 

Basic Training Chassis

 Brake system

Pneumatic diagram
Pneumatic diagram
Diagram for spring suspension

Basic Training Chassis

 Brake system

Pneumatic diagram
Pneumatic diagram
Diagram for air suspension 

Basic Training Chassis

 Brake system

Pneumatic diagram
Pneumatic diagram
Position text for diagram

Basic Training Chassis

 Brake system

Pneumatic diagram
Pneumatic diagram
Position text for diagram

Basic Training Chassis

 Brake system

Pneumatic diagram
Pneumatic diagram
Position text for diagram

Basic Training Chassis

 Brake system

Pneumatic diagram
Pneumatic diagram
Position text for diagram

Basic Training Chassis

 Brake system

Pneumatic diagram
Pneumatic diagram
Connection for the 
four‐way protection valve

Basic Training Chassis

 Brake system

Pneumatic diagram
Pneumatic diagram
For vehicle equipped trailer brake

Basic Training Chassis

 Brake system

Pneumatic diagram
Pneumatic diagram
Electrical component are
are drawn in diagram
are drawn in diagram  

Basic Training Chassis

 Brake system

Air brake system 
Air brake system
controlled by electric [EBS]
EBS principle

EBS (Electronically controlled brake system) is pneumatic brake system that is controlled 
electronically
electronically and is integrated into the vehicle
and is integrated into the vehicle’ss electronic system.
electronic system

Basic Training Chassis

 Brake system

Air brake system 
Air brake system
controlled by electric [EBS]
EBS principle

The feed section is similar to earlier pneumatic systems, however with EBS, all control section valves
have been replaced with electronically controlled modulator valves
valves..

 The brakes are operated by compressed air, but the actual 
regulation of the braking function is done by the EBS 
control module.

 Since the system is controlled electronically,
Since the system is controlled electronically it
it reacts very 
reacts very
quickly, which results in improved road safety.

Basic Training Chassis

 Brake system

Air brake system 
Air brake system
controlled by electric [EBS]
EBS description 
d & operation
 With the help of electronics, the EBS control module controls 
modulators that are similar to relay valves.

 The modulators, in turn, regulate the flow of air to the brake 
cylinders.

 The truck is fitted with load sensors that sense axle loads.

 Wheel sensors register the wheel’s speed, wear sensors monitor the amount of wear to the brake 
pads.

 This information is transmitted to the control module, which analyses and evaluates the signals from 
This information is transmitted to the control module which analyses and evaluates the signals from
the sensors.

Basic Training Chassis

 Brake system

Air brake system 
Air brake system
controlled by electric [EBS]
EBS description & operation

 Based
Based on this information, the control module determines the way in which the modulators should 
on this information the control module determines the way in which the modulators should
regulate brake pressure for the respective axles and wheels.

 The footbrake valve module sends both electrical and air pressure signals to the modulators.                      
Primarily only the electrical signal is used to operate the modulators.

 The air signal is there to take over in 
case
case of electrical failure.
of electrical failure

Basic Training Chassis

 Brake system

Air brake system 
Air brake system
controlled by electric [EBS]
EBS description & operation

 The system reacts very quickly,

quickly resulting in shorter braking distances
distances..

 Brake force is distributed more efficiently, both between the axles, and between the towing
vehicle and trailer, which improves stability.
stability.

 Brake force characteristics are adapted and optimized by more precise control.
control.

 Reduced and more even wear on brake linings and tyres

tyres..

Basic Training Chassis

 Brake system

Air brake system 
Air brake system
controlled by electric [EBS]
EBS related function
l df
The functions mentioned below are also related to and interact with EBS and are 
covered later
covered later.

 BCS (Braking compatibility system) 
BCS (Braking compatibility system) –– distributes brake force between the axles, 
depending on the load and the degree of wear on the brake linings. 

 ESP (Electronic stability program) –
ESP (Electronic stability program) – brakes the wheels individually in 
tractor‐‐trailer units when one or more of the wheels begins to lose 
tractor
traction
traction. The system stops a skid and prevents the vehicle from
The system stops a skid and prevents the vehicle from
rolling over. 

 TCS (Traction control system) –
TCS (Traction control system) – brakes one wheel that begins 
to spin, e.g. in slippery conditions. Power is transferred to the 
other wheel on the same axle.

Basic Training Chassis

 Brake system

Air brake system 
Air brake system
controlled by electric [EBS]
EBS management
EBS management 

Basic Training Chassis

 Brake system

Anti lock brake system [ABS]

Anti‐lock brake system [ABS]
ABS principle

 ABS (Anti
(Anti‐‐lock Brake System) is additional to the 
basic braking system and prevents the wheels 
from locking during braking.

 The advantage of ABS is that the brakes can make maximal use of the available friction with the    
surface of the road when braking. Braking distance is considerably shorter and the vehicle will be 
easier to handle during hard braking.
i t h dl d i h d b ki

Basic Training Chassis

 Brake system

Anti lock brake system [ABS]

Anti‐lock brake system [ABS]
ABS function
 When the vehicle’s brakes are applied and one of the wheels shows a tendency to lock, the 
control module receives a signal from the wheel speed sensor on that wheel. The information is 
processed in the control module, which sends an impulse to the solenoid control valve.

 The impulse acts on the solenoid control 
valve, which applies and releases the 
wheel brake. This takes place very  
quickly on the wheel that has shown a
quickly on the wheel  that has shown a 
tendency to lock.

Basic Training Chassis

 Brake system

Anti lock brake system [ABS]

Anti‐lock brake system [ABS]
ABS solenoid valve design

ISO symbol
Basic Training Chassis
 Brake system

Anti lock brake system [ABS]

Anti‐lock brake system [ABS]
ABS solenoid valve 
operation mode 

ISO symbol
Basic Training Chassis
 Brake system

Z cam brake mechanical

Z‐cam brake mechanical
Z‐cam brake description
 The name Z‐
The name Z‐cam comes from the brake anchorage pressure rods, which make a 
formation that looks like a Z.

 Both
Both shoes  are marked with arrows to indicate the 
shoes are marked with arrows to indicate the
direction of rotation.

Basic Training Chassis

 Brake system

Z cam brake mechanical

Z‐cam brake mechanical
Z‐cam brake design

Basic Training Chassis

 Brake system

Z cam brake mechanical

Z‐cam brake mechanical
Brake shoes design
 The brake shoe and brake lining is the component that is pressed against the brake drums when 
braking. 

 The brake linings are riveted to the brake shoe. 
The brake linings are riveted to the brake shoe

 The linings are manufactured of heat
The linings are manufactured of heat‐‐resistant material that enables them to withstand the 
heat that is generated by braking. 

 The wheel brakes have a primary/leading brake shoe 
and a secondary/trailing brake shoe relative to the 
wheel’ss direction  of rotation and the position of the 
wheel direction of rotation and the position of the
cam housing. It is important that the shoes are fitted 
correctly.       

Basic Training Chassis

 Brake system

Z cam brake mechanical

Z‐cam brake mechanical
Z‐cam brake function

 Z‐cam brakes are applied when the push 

rod presses the brake lever , which turns the brake cam. 

 There are two recesses at the inner end of the cam 
where two tappets are located. When the cam 
turns, the tappets act on their lifting units so 
that the brake shoes are pressed against the brake 
drum to brake the wheel.

Basic Training Chassis

 Brake system

Z cam brake mechanical

Z‐cam brake mechanical
Automatic adjuster

 The automatic mechanism has an inhibitor which ensures that the 
adjustment mechanism’s pinion can only be rotated in one 
direction during automatic adjustment of the brake shoes. 

 The inhibitor is released when the adjustment mechanism is 
pressed in for manual adjustment.

 The automatic adjustment mechanism always maintains the 
correct distance between the brake lining and brake drum.

Basic Training Chassis

 Brake system

Z cam brake mechanical

Z‐cam brake mechanical
Automatic adjuster

 When the brake is engaged, the cam screw moves 
Wh th b k i d th
in the direction of the blue arrow. Between the 
cam screw and the adjustment  pinion there is a 
ggap which corresponds to the distance between 
p p
the lining and drum brake. 

 When the distance between the lining and drum is excessive, the 
When the distance between the lining and drum is excessive the
adjustment pinion rotates to a new position. When the brake pedal 
is released, the cam screws turns to reduce the gap between the 
lining and drum.

Basic Training Chassis

 Brake system

THANK YOU
THANK YOU

Basic Training Chassis