BRAKING

BCOKIR
RA RCEOC
NG RRTOTORR
EC

In normal use While braking

During the braking phase, the vehicle lurches from the rear to the front (weight
transfer).
The front axle is overloaded and the rear axle is underloaded.
There is a risk of rear wheel lock (except in the case of ABS systems) and thus
dovetailing.

Note
The phenomenon of weight transfer directly depends on:
- the weight of the vehicle,
- its deceleration,
- its wheelbase (A),
- the position of centre of gravity (l, z).

Correctors provide rear braking pressure that is proportional to front pressure.

BRAKING SYSTEM TRAINING

 Braking corrector

Load-sensitive compensator
The load-sensitive compensator also takes vehicle weight into account (mainly on
commercial vehicles).

1 Load-sensitive compensator (attached to

the frame).
2 Indexing marks.
3 Brake fluid arrival and return pipes.
4 Rear axle.
5 Mounting to axle assembly.
6 Compensation spring.

The compensator is connected to the vehicle's rear axle by a spring (6) and lever (5).

It thus regulates the braking pressure of the rear brakes according to the vertical
movement and height of the chassis (weight on the axle assembly).

Pressure

Braking force

I1 Minimum unladen rear pressure p1 Minimum unladen rear braking

regulation point (p1). pressure.
I2 Maximum load rear pressure p2 Maximum load rear braking pressure.
regulation point (p2). p3 Front braking pressure.

BRAKING SYSTEM TRAINING

Braking corrector

At the start of the braking phase, the pressures (p1 and p2) are identical.

At a value determined by the Manufacturer, the pressure (p1) from the master cylinder
continues to increase in proportion to the force applied to the brake pedal. On the other
hand, the pressure of the rear brakes (p2) remains proportional to the pressure (p1) but
with a lower value.

Rest position
The spring (5) acts on the sliding piston (1) via a lever (6).

It creates a force (F3) that is proportional to the weight of the axle assembly and
maintains the sliding staged piston (1).

In this position, the valve (4) is open.

Frame of
1 Piston. vehicle
2 Compensator. S1 3
3 Valve spring. S2
4 Valve.
5 Spring. F1 F2 4
6 Lever.
F3
p1 Pressure from the master cylinder.
p2 Pressure to the rear brakes.
F1 F2
F1 Action of the pressure (p1) on the 1
annular surface (S1).
F2 Action of the pressure (p2) on the 2
annular surface (S2). p1 p2
F3 Action of the lever (6). L
6
L Spring length, vehicle unladen.
I Spring length, vehicle loaded.
FREIN-A1103SR0078

l
Axle
assembly

Hydraulic communication takes place through the compensator.

The pressure (p1) from the master cylinder is the same as the pressure (p2) to the rear
brakes.

BRAKING SYSTEM TRAINING

 Braking corrector

While braking
When the driver presses the brake pedal, the braking pressures (p1 and p2) increase
in the circuit (p1 = p2 always true).

The action (F2 + F4) becomes greater than actions (F1 + F3) due to the difference in
surfaces (S4 and S2) with (S1 = S2 > S4).

The staged piston (1) moves, and the valve (4) closes.

S4 S1 S2

4
F1 F2
F4

F3

F1 Action (p1) on the annular

F4
F1 F2 surface (S1).
1
F2 Action (p2) on the annular
surface (S2).
F3 Action of the lever (6).
p1 p2
F4 Action (p1) on the annular
surface (S4).
FREIN-A1103SR0079

Communication between the front and rear brakes is interrupted.

BRAKING SYSTEM TRAINING

Braking corrector

Pressure increase
When the compensator is closed, if the pressure of the master cylinder continues to
increase, operation takes place in two steps:

S4 S1
S2
F1
F4 F2 4

F1 Action (p1) on the annular surface F3

(S1).
F2
F2 Action (p2) on the annular surface F4
F1
(S2). 1
F3 Action of the lever (6).
F4 Action (p1) on the annular surface p1 p2
(S4).

FREIN-A1103SR0080
1st step: pressure (p1) becomes greater than pressure (p2).
The equilibrium of forces is broken, and the piston (1) moves.
The valve (4) opens, and communication between the front and rear brakes is re-
established.
2nd step: action (F2) re-displaces the piston (1) thanks to the difference in surfaces (S4
and S2) with (S1 = S2 > S4). The valve (4) closes again.
This piston oscillation movement around a position of equilibrium allows the rear
pressure to increase more slowly than the front pressure.

Special features of commercial vehicles

The conventional method for adjusting the braking corrector is difficult to perform on
loaded commercial vehicles, thus leading us to adjustment by tyre deflection as
described in the Workshop Repair Manual.

Possible tests:
Braking corrector.
- Compliance of pressure values with Manufacturer data
(possible adjustment).
- Absence of external leaks.
- Condition of the mechanical mounting.

BRAKING SYSTEM TRAINING

 DRUM BRAKE
DRUM BRAKE

3
10

8 8

11
11

1 2

12

4
FREIN-A1103SR0081

5
7
6
1 Leading (or compressed) shoe. 7 Retaining spring.
2 Trailing (or stretched) shoe. 8 Retaining springs.
3 Wheel cylinder. 9 Return spring.
4 Handbrake lever. 10 Automatic compensation mechanism.
5 Handbrake cable. 11 Side retainer springs ( 2).
6 Fixed stop. 12 Flange.

When the driver presses the brake pedal, the pressure created in the wheel cylinder
(3) spreads the shoes (1 and 2) and presses them against the drum.

The shoes are returned to their initial position by the return spring.

BRAKING SYSTEM TRAINING

Drum brake

Drum

1 Drum.
2 Braking surface.
3 Hub bearing. O
 Drum internal diameter.

FREIN-11103SR0090

This is a friction component whose internal diameter is composed of a surface (2) on

which the brake pads are applied.

Its other function is to protect the braking system from external elements:
- bad weather,
- salt for snow removal,
- gravel projections.

- Be careful of brake dust when removing the drum.

- The minimum thickness is engraved on the drum.

Possible tests:
Drum. - Absence of etching on the braking surface of brake
shoes.
- Absence of bluish colour on the braking surface of
brake shoes (overheating).
- Drum ovality (dial gauge).
- Drum wear (nominal measurement).

BRAKING SYSTEM TRAINING

 Drum brake

Brake shoes
2
The brake shoe is composed of a
pad (2) glued onto a rigid steel
support (3).

1 Handbrake lever.
2 Friction lining.
e
3 Rigid support.

FREIN-A1103SR0082
e Thickness of brake pads.

Characteristics
The two main characteristics required for optimum operation of rear brakes are:
Maintain the coefficient of friction independently of:
- Drum rotation speed.
- Braking force.
- Temperature reached during braking.
- Resist wear while not harming the drum braking surface.

Notes
- The brake shoes centre themselves and take as peripheral a position as
possible (improved braking).
- The leading lining wears faster.
- The friction surface between the brake shoes is different.
- Friction is unequal over the entire surface of brake shoes.

- After replacing brake shoes, you must press the brake pedal several
times to bring the shoes against the drum (danger of inefficient brakes)
prior to a road test.
- Be careful of brake dust during removal.

Possible tests: - Thickness of brake pads.

- Cleanliness (not greasy).
Brake shoes. - Condition of the shoe braking surface.

BRAKING SYSTEM TRAINING

Drum brake

Parking brake
3
10 16

1 Leading (or compressed) shoe. 8

2 Trailing (or stretched) shoe. 8
3 Wheel cylinder.
4 Handbrake lever.
5 Handbrake cable.
6 Fixed stop. 2
8 Retaining springs.
9 Return spring. 1
10 Automatic compensation
mechanism.
16 Handbrake lever axis. 4

FREIN-A1103SR0083
5
6

Under the force of the cable (5), the lever (4) turns on its axis (16) and moves the shoes
(1 and 2) against the drum via the assembly (10).
The rear wheels lock.
When the handbrake is released, the return spring (9) returns the shoes to their initial
position.
The brake drum can once again turn freely.

Handbrake released Handbrake on

Notes
- When the handbrake is applied, the automatic compensation mechanism does
not work. It is considered to be a spacer connecting the lever and the leading
shoe.
- The handbrake is not a play compensation system, and must only be adjusted
when replacing shoes or control lever cables.

BRAKING SYSTEM TRAINING

 Drum brake

Wheel cylinder
4 5 4
1 2

FREIN-A1103SR0086
3
1 Leading shoe. 4 Pistons.
2 Trailing shoe. 5 Brake fluid.
3 Wheel cylinder body.

Under the action of brake fluid pressure, the pistons slide to the outside of the cylinder
and displace the shoes against the drum.

3 Wheel cylinder.
6 Flange.
7 Bleed screw and protective cap.
8 Rigid pipe.

Note
- Use of a pipe wrench to unlock a rigid pipe union is strongly recommended.

- After replacing wheel cylinders, you must press the brake pedal several
times to bring the shoes against the drum (danger of inefficient brakes)
prior to a road test.
- Braking pressures must be checked after replacing a cylinder.

Possible tests:
Wheel cylinder. - Absence of external leak (may require dust seal
removal).
- Free sliding of pistons.

BRAKING SYSTEM TRAINING

Drum brake

Automatic compensation system

Its purpose is to maintain constant clearance between the drum and the shoes as they
become worn.

Identification of the automatic compensation mechanism requires removal of the drum

since it differs according to the Manufacturer.

1 Leading shoe. 5 Notched tumblewheel.

2 Return spring. 6 Threaded linkage.
3 Tapped linkage. 7 Spring lug.
4 Anti-rotation lug. 8 Spacer.

Description
The automatic compensation mechanism is composed of a tapped linkage (3) which
receives the threaded linkage at its end (6). The latter includes the notched
tumblewheel (5) whose position determines the clearance between the shoes and the
drum.

BRAKING SYSTEM TRAINING

 Drum brake

While braking

1 Leading shoe. 7 Spring lug.

2 Return spring. 8 Spacer.
5 Notched tumblewheel.

The shoes separate and free the assembly from the wear compensation mechanism.

The lug (7) unscrews and displaces the notched tumblewheel (5) via its deformation:
the wear compensation mechanism becomes longer.

If the brake shoe movement is low, the force exerted by the lug (7) and its deformation
are not sufficient to pull the notched tumblewheel (5): the wear compensation
mechanism does not become longer.

When releasing brakes

The shoes are returned to their rest position by the return spring (2).

The spacer (8) returns to its initial position, and the lug (7) passes the notches of the
notched tumblewheel (5).

This notch passage corresponds to the clearance between the shoes and the drum.

Automatic lengthening of the wear compensation mechanism is rendered irreversible.

BRAKING SYSTEM TRAINING

Drum brake

- Any adjustments outside these operations is prohibited.

- During the removal/fitting phase, remember not to inverse the wear
compensation mechanism assembly from its respective side of the
vehicle: the directions of the metric step and the notched sector are
different.
- In some cases, the automatic compensation system must be
disengaged to remove the drum without damaging the various
components.

A B

A Left step (metric).

B Right step (metric).

Possible tests:
Automatic compensation. - Automatic compensation system conformity and
operation.

BRAKING SYSTEM TRAINING

 DISC BRAKE
DISC BRAKE

All vehicles are now equipped with front disc brakes. Many vehicles are also equipped
with rear disc brakes.

The brake disc is a thick steel or cast iron component whose surfaces are flat and
parallel. It is:
- positioned by mounting bolts,
- maintained by wheel bolts.

1 Brake disc. 4 brake calliper.

2 Mounting bolts ( 2). 5 Hub nut.
3 Wheel bolt holes ( 4).

BRAKING SYSTEM TRAINING

 Disc brake

Brake discs
Ventilated brake disc Full brake disc

1 Brake calliper. 4 Recess.

2 Brake pads. e Brake disc thickness.
3 Ventilated brake disc.

Ventilated brake discs (3) include a series of recesses (4) included to improve cooling.

Notes
- Brake discs are replaced in pairs on the same axle with new brake pads for
optimum braking effectiveness.
- Since brake discs cannot be reground, they must be replaced in the case of
excessive scratches or wear.
- The minimum thickness is engraved on the brake disc.

Possible tests:
Brake disc. - Absence of bluish colour on the braking surface of pads.
- Absence of cracks or scratches.
- Wear (nominal measurement).
- Warping.

BRAKING SYSTEM TRAINING

 Disc brake

Floating calliper

1 Calliper.
2 Hydraulic piston.
3 Brake pads.
4 Brake disc.
5 Deformable seal.
6 Hole for arrival of brake fluid from
the master cylinder.

There are two steps in the operation of floating calliper disc brakes:
- 1st step: pressing of one pad.

The pressure from the input hole (6) acts on the piston (2) which presses the pad (3)
against the disc (4).
- 2nd step: pressing of the second pad.

Now, the calliper (1) moves axially and presses the second pad (3) on the other side of
the disc (4).

The actions of brake pads (3) are opposite and of the same power.

The piston (2) is returned to its rest position via a square seal (5) installed in a machined
throat in the calliper (1).

BRAKING SYSTEM TRAINING

Disc brake

1 Calliper. A Seal at rest.

2 Hydraulic piston. B Seal deformed when braking.
5 Deformable seal.

When braking, the displacement of the hydraulic piston (2) causes deformation (B) of
the seal (5).

When the driver releases the pedal, the pressure drops in the circuit and allows the seal
(5) to bring the piston (2) back to its original position (A).

At the same time, the (tolerated) brake disc run-out also helps to return the piston.

This allows the disc to rotate freely and allows the pads to be active when driving
conditions require braking.

In the absence of braking, the piston is maintained in position by its sealing joint. This
position maintenance ensures a constant operating clearance between the brake pads
and the brake disc according to their wear.

BRAKING SYSTEM TRAINING

 Disc brake

Fixed calliper
7

1 Calliper. 5 Internal brake fluid channels.

2 Hydraulic pistons. 6 Deformable sealing joint.
3 Brake pads. 7 Bleed screw.
4 Brake disc. E Hole for arrival of brake fluid from the
master cylinder.

Operation of fixed calliper disc brakes is different from those with a sliding calliper. The
pressure in the hydraulic circuit (5) acts simultaneously on the pistons (2) and presses
the pads (3) on the disc (4).

The actions of brake pads (3) are opposite and of the same power.

BRAKING SYSTEM TRAINING

Disc brake

Rear brake calliper

1 Handbrake cable protective sheath. 8 Piston.

2 Handbrake cable. 9 Brake pad.
3 Brake calliper. 10 Brake disc.
4 Actuating lever. 11 Handbrake lever return spring.
5 Actuating shaft eccentric crown. 12 Tapped piston.
6 Pressure part. 13 Seal.
7 Threaded drive pin. E Brake fluid entry hole.

The rear brake calliper receives the parking brake system.

Regardless of brake pad wear, constant braking efficacy and parking brake travel must
be maintained.

Consequently, when braking, the pressure from the hydraulic circuit (E) increases and
displaces the piston (8) hydraulically in translation movement to press the brake pads
against the disc (10).

In its translation movement, the piston (8) mechanically pulls the tapped piston (12),
which can only turn around the threaded drive pin (7).

This drive pin is blocked for rotation movement, but free for translation movement.

Notes
- Return to the resting position and compensation for the wear of pads is based
on the same principle as the sliding calliper.
- When replacing rear brake pads, the piston must be turned back on itself in
order to push it back.

BRAKING SYSTEM TRAINING

 Disc brake

Parking brake
Under force from the handbrake cable (2), the lever (4), whose crown (5) is eccentric,
acts on the piston (8) mechanically via the pin (7) and the pressure part (6).

The piston (8) presses the pad (9) against one side of the brake disc (10) and, in
reaction, the body of the calliper (3) also displaces the second pad against the other
side. The brake disc is now tightened and the rear wheels lock.

When releasing the handbrake, the spring (11) located on the calliper (3) returns the
actuating lever (4) to its initial position.

The brake disc can once again turn freely.

Note
Each rear brake has its own cable.

Possible tests: - Sliding of the mobile section of the calliper (floating

calliper).
Calliper. - Seepage of brake fluid by the piston.
- Displacement of the piston in its cylinder liner.

BRAKING SYSTEM TRAINING

Disc brake

Brake pads

1 Metallic support.
2 Friction material (lining).
3 Anti-noise shims (vary
according to models).
e Pad thickness.

The brake pad is composed of a friction material (2) cemented to a metallic support (1).
The presence of shims (3) on some vehicles reduces braking noise. These shims differ
according to the installation.
The brake pads are fitted in the calliper whose role is to tighten them on the disc when
the brake pedal is pressed.
Regardless of wear, its main characteristic is to present a large coefficient of friction
independently of:
- braking pressure,
- vehicle speed,
- temperature reached during braking,
- bad weather.

Notes
- The function and signal of the brake pad wear warning light on the instrument
panel are no longer used.
- Brake pads must be replaced on the same axle assembly at the same time.

- After replacing the brake pads, you must press the brake pedal several
times to bring the pads against the disc (danger of inefficient brakes)
prior to a road test.

Possible tests: - Brake pad thickness.

- Uneven wear of brake pads on the same side.
Brake pads. - Cleanliness of brake pads.

BRAKING SYSTEM TRAINING