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POWER BRAKE UNIT OPERATION, DIAGNOSIS, AND SERVICE 105
Objectives ,[object Object],[object Object],[object Object],[object Object]
Objectives ,[object Object],[object Object],[object Object]
THE NEED FOR POWER BRAKE ASSIST
The Need for Power Brake Assist ,[object Object],[object Object],[object Object]
The Need for Power Brake Assist ,[object Object],[object Object]
Figure 105-1   Typical vacuum brake booster assembly. The vacuum hose attaches to the intake manifold of the engine. The brake pedal travel sensor is an input sensor for the antilock braking system.
Figure 105-2   A wide brake pedal allows two-foot braking if power assist is lost.
PRINCIPLES OF VACUUM
Principles of Vacuum ,[object Object]
Principles of Vacuum ,[object Object],[object Object]
Principles of Vacuum ,[object Object]
Figure 105-3   Atmospheric pressure varies with altitude.
Principles of Vacuum ,[object Object],[object Object]
Principles of Vacuum ,[object Object],[object Object]
Principles of Vacuum ,[object Object],[object Object]
Principles of Vacuum ,[object Object],[object Object],[object Object]
Principles of Vacuum ,[object Object],[object Object]
Principles of Vacuum ,[object Object],[object Object]
Principles of Vacuum ,[object Object],[object Object],[object Object]
Principles of Vacuum ,[object Object],[object Object]
Principles of Vacuum ,[object Object],[object Object],[object Object]
Figure 105-4   A belt-driven auxiliary vacuum pump.
Figure 105-5   An electrically powered vacuum pump.
VACUUM BOOSTER THEORY
Vacuum Booster Theory ,[object Object],[object Object]
Vacuum Booster Theory ,[object Object],[object Object]
Vacuum Booster Theory ,[object Object],[object Object]
Figure 105-6   Vacuum brake boosters operate on the principle of pressure differential.
CHARCOAL FILTER
Charcoal Filter ,[object Object]
Charcoal Filter ,[object Object]
Figure 105-7   The charcoal filter traps gasoline vapors that are present in the intake manifold and prevents them from getting into the vacuum chamber of the booster.
VACUUM CHECK VALVE
Vacuum Check Valve ,[object Object],[object Object]
Vacuum Check Valve ,[object Object],[object Object]
Vacuum Check Valve ,[object Object]
Vacuum Check Valve ,[object Object]
Figure 105-8 (a)   Many vacuum brake booster check valves are located where the vacuum hose from the engine (vacuum source) attaches to the vacuum booster.
Figure 105-8 (b)   This one-way valve prevents the loss of vacuum when the engine is off. The diaphragm inside allows air to flow in one direction only.
VACUUM BRAKE BOOSTER OPERATION
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object]
Vacuum Brake Booster Operation ,[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object],[object Object]
Figure 105-10   Cross-sectional view of a typical vacuum brake booster assembly.
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Figure 105-11   In the release position (brake pedal up), the vacuum is directed to both sides of the diaphragm.
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object],[object Object]
Figure 105-12   Simplified diagram of a vacuum brake booster in the apply position. Notice that the atmospheric valve is open and air pressure is being applied to the diaphragm.
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
Figure 105-13   Cross section of a vacuum brake booster in the hold position with both vacuum and atmospheric valves closed. Note that the reaction force from the brake fluid pressure is transferred back to the driver as a reaction force to the brake pedal.
Vacuum Brake Booster Operation ,[object Object],[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object],[object Object]
Vacuum Brake Booster Operation ,[object Object],[object Object]
DUAL- (TANDEM-) DIAPHRAGM VACUUM BOOSTERS
Dual- (Tandem-) Diaphragm Vacuum Boosters ,[object Object]
Figure 105-14   Cutaway showing a dual-diaphragm (tandem) vacuum brake booster.
BRAKE ASSIST SYSTEM
Brake Assist System ,[object Object]
Brake Assist System ,[object Object],[object Object]
Brake Assist System ,[object Object],[object Object]
Brake Assist System ,[object Object],[object Object]
Brake Assist System ,[object Object],[object Object]
Brake Assist System ,[object Object],[object Object]
Figure 105-16   When the brake assist function operates, the brake force is much higher than normal.
Figure 105-17   Typical adjustable pushrod. This adjustment is critical for the proper operation of the braking system. If the pushrod is too long, the brakes may be partially applied during driving. If the rod is too short, the brake pedal may have to be depressed farther down before the brakes start to work.
VACUUM BOOSTER OPERATION TEST
Vacuum Booster Operation Test ,[object Object],[object Object]
Vacuum Booster Operation Test ,[object Object],[object Object],[object Object]
Vacuum Booster Operation Test ,[object Object]
VACUUM BOOSTER LEAK TEST
Vacuum Booster Leak Test ,[object Object],[object Object]
Vacuum Booster Leak Test ,[object Object],[object Object]
Vacuum Booster Leak Test ,[object Object],[object Object]
Vacuum Booster Leak Test ,[object Object]
Vacuum Booster Leak Test ,[object Object],[object Object]
Vacuum Booster Leak Test ,[object Object]
HYDRAULIC SYSTEM LEAK TEST
Hydraulic System Leak Test ,[object Object]
Hydraulic System Leak Test ,[object Object],[object Object]
Hydraulic System Leak Test ,[object Object],[object Object]
PUSHROD CLEARANCE ADJUSTMENT
Pushrod Clearance Adjustment ,[object Object],[object Object]
Pushrod Clearance Adjustment ,[object Object]
Pushrod Clearance Adjustment ,[object Object],[object Object]
Figure 105-16   When the brake assist function operates, the brake force is much higher than normal.
Figure 105-17   Typical adjustable pushrod. This adjustment is critical for the proper operation of the braking system. If the pushrod is too long, the brakes may be partially applied during driving. If the rod is too short, the brake pedal may have to be depressed farther down before the brakes start to work.
Figure 105-18 (a)   Typical vacuum brake booster pushrod gauging tool. (a) The tool is first placed against the mounting flange of the master cylinder and the depth of the piston determined.
Figure 105-18 (b)   Typical vacuum brake booster pushrod gauging tool. (b) The gauge is then turned upside down and used to gauge the pushrod length. Some vacuum brake boosters do not use adjustable pushrods. If found to be the incorrect length, a replacement pushrod of the correct length should be installed.
VACUUM BOOSTER DISASSEMBLY AND SERVICE
Vacuum Booster Disassembly and Service  ,[object Object]
Vacuum Booster Disassembly and Service  ,[object Object]
Vacuum Booster Disassembly and Service  ,[object Object],[object Object],?
Figure 105-19   A holding fixture and a long tool being used to rotate the two halves of a typical vacuum brake booster.
Figure 105-20   Exploded view of a typical dual-diaphragm vacuum brake booster assembly.
HYDRO-BOOST HYDRAULIC BRAKE BOOSTER
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object]
Figure 105-21   Hydro-Boost unit attaches between the bulkhead and the master cylinder and is powered by the power steering pump.
Figure 105-22   Exploded view of the Hydro-Boost unit.
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object],[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object],[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object],[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object]
Figure 105-23   A Hydro-Boost hydraulic booster in the unapplied position.
Figure 105-24   A Hydro-Boost hydraulic booster as the brakes are applied.
Figure 105-25   A Hydro-Boost hydraulic booster in the holding position.
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object],[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object],[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object],[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object],[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object]
Figure 105-26   A typical Hydro-Boost hydraulic line arrangement showing the pump, steering gear, and brake booster assembly.
Figure 105-27   Pressure and flow analyzer installation to check the power steering pump output.
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object]
Hydro-Boost Hydraulic Brake Booster ,[object Object],[object Object],[object Object]
HYDRO-BOOST SYMPTOM-BASED GUIDE
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
Hydro-Boost Symptom-Based Guide ,[object Object],[object Object],[object Object]
TECH TIP ,[object Object],[object Object],BACK TO  PRESENTATION ,[object Object],[object Object],[object Object],[object Object]
TECH TIP ,[object Object],[object Object],BACK TO  PRESENTATION ,[object Object]
FREQUENTLY ASKED QUESTION ,[object Object],[object Object],? BACK TO  PRESENTATION ,[object Object],[object Object],[object Object],[object Object],[object Object]
TECH TIP ,[object Object],[object Object],BACK TO  PRESENTATION ,[object Object],[object Object]

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Halderman ch105 lecture

  • 1. POWER BRAKE UNIT OPERATION, DIAGNOSIS, AND SERVICE 105
  • 2.
  • 3.
  • 4. THE NEED FOR POWER BRAKE ASSIST
  • 5.
  • 6.
  • 7. Figure 105-1 Typical vacuum brake booster assembly. The vacuum hose attaches to the intake manifold of the engine. The brake pedal travel sensor is an input sensor for the antilock braking system.
  • 8. Figure 105-2 A wide brake pedal allows two-foot braking if power assist is lost.
  • 10.
  • 11.
  • 12.
  • 13. Figure 105-3 Atmospheric pressure varies with altitude.
  • 14.
  • 15.
  • 16.
  • 17.
  • 18.
  • 19.
  • 20.
  • 21.
  • 22.
  • 23. Figure 105-4 A belt-driven auxiliary vacuum pump.
  • 24. Figure 105-5 An electrically powered vacuum pump.
  • 26.
  • 27.
  • 28.
  • 29. Figure 105-6 Vacuum brake boosters operate on the principle of pressure differential.
  • 31.
  • 32.
  • 33. Figure 105-7 The charcoal filter traps gasoline vapors that are present in the intake manifold and prevents them from getting into the vacuum chamber of the booster.
  • 35.
  • 36.
  • 37.
  • 38.
  • 39. Figure 105-8 (a) Many vacuum brake booster check valves are located where the vacuum hose from the engine (vacuum source) attaches to the vacuum booster.
  • 40. Figure 105-8 (b) This one-way valve prevents the loss of vacuum when the engine is off. The diaphragm inside allows air to flow in one direction only.
  • 41. VACUUM BRAKE BOOSTER OPERATION
  • 42.
  • 43.
  • 44.
  • 45.
  • 46. Figure 105-10 Cross-sectional view of a typical vacuum brake booster assembly.
  • 47.
  • 48.
  • 49.
  • 50.
  • 51.
  • 52.
  • 53.
  • 54. Figure 105-11 In the release position (brake pedal up), the vacuum is directed to both sides of the diaphragm.
  • 55.
  • 56.
  • 57.
  • 58.
  • 59.
  • 60.
  • 61.
  • 62.
  • 63. Figure 105-12 Simplified diagram of a vacuum brake booster in the apply position. Notice that the atmospheric valve is open and air pressure is being applied to the diaphragm.
  • 64.
  • 65.
  • 66.
  • 67.
  • 68.
  • 69. Figure 105-13 Cross section of a vacuum brake booster in the hold position with both vacuum and atmospheric valves closed. Note that the reaction force from the brake fluid pressure is transferred back to the driver as a reaction force to the brake pedal.
  • 70.
  • 71.
  • 72.
  • 73. DUAL- (TANDEM-) DIAPHRAGM VACUUM BOOSTERS
  • 74.
  • 75. Figure 105-14 Cutaway showing a dual-diaphragm (tandem) vacuum brake booster.
  • 77.
  • 78.
  • 79.
  • 80.
  • 81.
  • 82.
  • 83. Figure 105-16 When the brake assist function operates, the brake force is much higher than normal.
  • 84. Figure 105-17 Typical adjustable pushrod. This adjustment is critical for the proper operation of the braking system. If the pushrod is too long, the brakes may be partially applied during driving. If the rod is too short, the brake pedal may have to be depressed farther down before the brakes start to work.
  • 86.
  • 87.
  • 88.
  • 90.
  • 91.
  • 92.
  • 93.
  • 94.
  • 95.
  • 97.
  • 98.
  • 99.
  • 101.
  • 102.
  • 103.
  • 104. Figure 105-16 When the brake assist function operates, the brake force is much higher than normal.
  • 105. Figure 105-17 Typical adjustable pushrod. This adjustment is critical for the proper operation of the braking system. If the pushrod is too long, the brakes may be partially applied during driving. If the rod is too short, the brake pedal may have to be depressed farther down before the brakes start to work.
  • 106. Figure 105-18 (a) Typical vacuum brake booster pushrod gauging tool. (a) The tool is first placed against the mounting flange of the master cylinder and the depth of the piston determined.
  • 107. Figure 105-18 (b) Typical vacuum brake booster pushrod gauging tool. (b) The gauge is then turned upside down and used to gauge the pushrod length. Some vacuum brake boosters do not use adjustable pushrods. If found to be the incorrect length, a replacement pushrod of the correct length should be installed.
  • 109.
  • 110.
  • 111.
  • 112. Figure 105-19 A holding fixture and a long tool being used to rotate the two halves of a typical vacuum brake booster.
  • 113. Figure 105-20 Exploded view of a typical dual-diaphragm vacuum brake booster assembly.
  • 115.
  • 116.
  • 117.
  • 118. Figure 105-21 Hydro-Boost unit attaches between the bulkhead and the master cylinder and is powered by the power steering pump.
  • 119. Figure 105-22 Exploded view of the Hydro-Boost unit.
  • 120.
  • 121.
  • 122.
  • 123.
  • 124. Figure 105-23 A Hydro-Boost hydraulic booster in the unapplied position.
  • 125. Figure 105-24 A Hydro-Boost hydraulic booster as the brakes are applied.
  • 126. Figure 105-25 A Hydro-Boost hydraulic booster in the holding position.
  • 127.
  • 128.
  • 129.
  • 130.
  • 131.
  • 132.
  • 133.
  • 134. Figure 105-26 A typical Hydro-Boost hydraulic line arrangement showing the pump, steering gear, and brake booster assembly.
  • 135. Figure 105-27 Pressure and flow analyzer installation to check the power steering pump output.
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Notas del editor

  1. Figure 105-1 Typical vacuum brake booster assembly. The vacuum hose attaches to the intake manifold of the engine. The brake pedal travel sensor is an input sensor for the antilock braking system.
  2. Figure 105-2 A wide brake pedal allows two-foot braking if power assist is lost.
  3. Figure 105-3 Atmospheric pressure varies with altitude.
  4. Figure 105-4 A belt-driven auxiliary vacuum pump.
  5. Figure 105-5 An electrically powered vacuum pump.
  6. Figure 105-6 Vacuum brake boosters operate on the principle of pressure differential.
  7. Figure 105-7 The charcoal filter traps gasoline vapors that are present in the intake manifold and prevents them from getting into the vacuum chamber of the booster.
  8. Figure 105-8 (a) Many vacuum brake booster check valves are located where the vacuum hose from the engine (vacuum source) attaches to the vacuum booster.
  9. Figure 105-8 (b) This one-way valve prevents the loss of vacuum when the engine is off. The diaphragm inside allows air to flow in one direction only.
  10. Figure 105-10 Cross-sectional view of a typical vacuum brake booster assembly.
  11. Figure 105-11 In the release position (brake pedal up), the vacuum is directed to both sides of the diaphragm.
  12. Figure 105-12 Simplified diagram of a vacuum brake booster in the apply position. Notice that the atmospheric valve is open and air pressure is being applied to the diaphragm.
  13. Figure 105-13 Cross section of a vacuum brake booster in the hold position with both vacuum and atmospheric valves closed. Note that the reaction force from the brake fluid pressure is transferred back to the driver as a reaction force to the brake pedal.
  14. Figure 105-14 Cutaway showing a dual-diaphragm (tandem) vacuum brake booster.
  15. Figure 105-16 When the brake assist function operates, the brake force is much higher than normal.
  16. Figure 105-17 Typical adjustable pushrod. This adjustment is critical for the proper operation of the braking system. If the pushrod is too long, the brakes may be partially applied during driving. If the rod is too short, the brake pedal may have to be depressed farther down before the brakes start to work.
  17. Figure 105-16 When the brake assist function operates, the brake force is much higher than normal.
  18. Figure 105-17 Typical adjustable pushrod. This adjustment is critical for the proper operation of the braking system. If the pushrod is too long, the brakes may be partially applied during driving. If the rod is too short, the brake pedal may have to be depressed farther down before the brakes start to work.
  19. Figure 105-18 (a) Typical vacuum brake booster pushrod gauging tool. (a) The tool is first placed against the mounting flange of the master cylinder and the depth of the piston determined.
  20. Figure 105-18 (b) Typical vacuum brake booster pushrod gauging tool. (b) The gauge is then turned upside down and used to gauge the pushrod length. Some vacuum brake boosters do not use adjustable pushrods. If found to be the incorrect length, a replacement pushrod of the correct length should be installed.
  21. Figure 105-19 A holding fixture and a long tool being used to rotate the two halves of a typical vacuum brake booster.
  22. Figure 105-20 Exploded view of a typical dual-diaphragm vacuum brake booster assembly.
  23. Figure 105-21 Hydro-Boost unit attaches between the bulkhead and the master cylinder and is powered by the power steering pump.
  24. Figure 105-22 Exploded view of the Hydro-Boost unit.
  25. Figure 105-23 A Hydro-Boost hydraulic booster in the unapplied position.
  26. Figure 105-24 A Hydro-Boost hydraulic booster as the brakes are applied.
  27. Figure 105-25 A Hydro-Boost hydraulic booster in the holding position.
  28. Figure 105-26 A typical Hydro-Boost hydraulic line arrangement showing the pump, steering gear, and brake booster assembly.
  29. Figure 105-27 Pressure and flow analyzer installation to check the power steering pump output.