Welcome To

Brakes India Limited

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 Presentation
To

On

Brake System

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 The Company
Established 1962
Net Worth Rs.230 Cr
Sales(06-07) Rs.1050 Cr
Employees 2840
Engineers 666
Built up Space 950,000 Sq.ft
Mfg Locations 6
Certifications TS 16949
ISO 14001
TPM*
Deming**

* 3 Sites ** Foundry Only

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 Manufacturing Locations

Gurgaon (Delhi)

Halol (Gujarat)
Waki (Pune)

Sholinghur (110 Kms)

Padi (Chennai)
Polambakkam (100 Kms)

Nanjangud (Karnataka)

In-House Foundry, Press Shop, Process Shop, Tool Room

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 Service & Aftermarket Support

Delhi
(2500 Kms)

Kolkatta
(1680 Kms)
Pune
(1200 Kms)

35 Trained Field Engineers 5 Parts Warehouses

100+ Training Sessions
200+ Distributor Branches
Chennai
64 Mechanic Meets
40,000+ Dealers
2100+ Service Visits
2700 Part Numbers

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 OE Customer Base

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 Engineering Research & Development
Engineers 125
% Total Staff 4%
Spend% of Sales 2.3%

Capability to Design,
Develop, Prototype,
Test and Validate

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 SUPPORTED BY HEALTHY ENGINEERING

670 ENGINEERS FOR

PRODUCT SUPPORT

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MANUFACTURING & INSPECTION PROCESES

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 MODERN FOUNDRY

PRESSURE DIE CASTING UNIT

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 MANUFACTURING UNIT C N C MACHINING

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 MANUFACTURIN UNIT C N C MACHINING

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 DEGREASING PLANT

ALL CYLINDERS DEGREASED BEFORE ASSEMBLY

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 MASTER CYLINDER ASSEMBY &TESTING

100% CYLINDERS ARE TESTED FOR HIGH PRESSURE/LOW PRESSURE / LEAK.

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 COMPUTER AIDED INSPECTION

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 BRAKE ASSEMBLY

W/ CYL MOUNTED

SHOE ASSEMBLY,ADJUSTER &

SPRING,SHOE HOLD ON CLIP
FITMENT

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 BRAKE ASSEMBLY TESTING

100% BRAKE ASSEMBLIES ARE TESTED FOR FUNCTIONAL /SET DIA / LEAK

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 Development & Testing
CALIPER BRAKE UNDER TESTING

DISC

DISC TEMPERATURE GOES BEYOND 500 DEG C

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 E R & D HOT OVEN TEST

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 E R & D -DYNO TESTING

CALIPER VALIDATION TEST

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Dynamometers Development & Testing
Test Rigs

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 Development & Testing

Noise Study Hot Oven Test Test Track Testing

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 Product Range
Brake System

Foundation Brakes Actuation System Components

Disc Drum Tractor M.Cyl Booster Valves Low Brake Fluid

Expansion Dot 3
Hose Dot 4
Simplex Drum Br. AS/AS LSC LCRV
Colette Simplex A/A Dry Disc CV/CV Non-LSC PCRV
Single Pot Duplex Wet Disc CV GP
Twin Pot LSPV Friction Materials
Duo Duplex Hyd Act. AS
Reverse Pin Duo Servo
ABS
S Cam
Z Cam
Clutch M.Cyl Slave Cyl
SAW

AS, CV

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 Why Braking system ?
3 basic function of braking system
• Decelerate a vehicle including stopping.
• Maintain vehicle speed during downhill operation.
• Hold a vehicle stationary on a grade.

“Brakes stop wheels – not vehicles”

Speaker notes
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 PRODUCT
KNOWLEDGE
Brake System
Vehicle layout
Tandem Master Cylinder
functions
Servo Assembly
Parts &
Caliper Assembly
Drum brake Assembly
Valve

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•The service braking system consists of front ventilated
disc with twin pot caliper and rear drum brakes with
auto adjuster.

•No adjustment required for front and rear brakes.

•These are hydraulically operated and a dual hydraulic

split circuit is provided for front and rear brakes.

•In the even of one circuit fails, the other remains

unaffected and the vehicle can be brought to halt.

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The hydraulic pressure is applied from the tandem
master cylinder to the front calipers and rear wheel
cylinders through suitable bundy tubes/flexible hoses.

The pistons inside the Calipers / wheel cylinders move

out, forcing the brake pads/shoes on the disc / drum,
and applying the brakes.

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To reduce pedal effort, a twin diaphragm vacuum
booster is fitted between brake pedal and tandem
master cylinder.

In the event of servo unit fails, the push rod still acts
mechanically to provide non-assisted braking.

The vacuum in the system is generated by vacuum

pump in case of diesel vehicle.

There is no vacuum pump for petrol vehicle.

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The parking brake is a mechanical lever
type, console-mounted cable operated
acting on rear wheels.

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Load sensing pressure-reducing valve
(LSPV) is provided in rear brake circuit
to avoid locking of rear wheels and
skidding of the vehicle for non-ABS
versions.

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 INSTALLATION LAYOUT
RRH DRUM BRAKE

F-RH CALIPER TO VACCUM PUMP

STMC ASSY
F-LH CALIPER

LCRV

RLH DRUM BRAKE

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 PRODUCT
Need for booster KNOWLEDGE
Classification VACUUM BOOSTER
Parts & functions

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 Need for booster

Present day automobiles are designed to run at very high speed (150 –
250 Kmph)

Since, inertia of these vehicles is very high, Braking system should be

able to absorb this inertia with least time and pedal effort.

With the conventional mechanical systems, which are less efficient

requires high effort to reach the requisite decelaration.

Hence alternate systems had been thought of to reduce the effort

and to improve the driver's comfort.

Vacuum boosters serves the above purpose. This equipment multiplies

the pedal-effort into pre-detemined ratio with the aid of vacuum.

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 Need for booster

PROVIDES POWER ASSISTANCE TO REDUCE

THE AMOUNT OF BRAKE PEDAL EFFORT
REQUIRED BY THE DRIVER.

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 Parts & functions

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 The Booster in Action

The device needs a vacuum source to operate.

In Petrol Engine, the engine provides a vacuum

suitable for the booster.

In diesel-powered vehicles must use a separate

vacuum pump.

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 The Booster in Action

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 Input rod plunger valve assembly

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Valve body and diaphragm plate assembly

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 TANDEM BOO STER

A) Air / vacuum passage

at rest condition

Air

Induction manifold/
Vacuum pump

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 TANDEM BOOSTER

Actuated condition

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DON’T DISTRUBE
THE OUTPUT
ROD STANDARD
OUT

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 VACCUM LEVEL CHECKING PROCEDURE

TO VACCUM PUMP

VACCUM PUMP

VACCUM GAUGE

650 - 700 Hg mm (-ve)

STMC ASSY

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TECHNICAL SPECIFICATIONS

VACCUME BOOSTER

SIZE : 9” + 8” DIA TANDEM BOOSTER

BOOST RATIO : 9.5 :1 For Diesel Vehicle

: 8:1 For Petrol vehicle

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 MASTER CYLINDER

GENERATES HYDRAULIC
PRESSURE TO APPLY THE DISC
& DRUM BRAKES

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 INSIDE THE TANDEM MASTER CYLINDER

RESERVOIR

SECONDARY
PLUNGER
PRIMARY PLUNGER

TO PEDAL

SPRING
BRAKE LINES

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HYDRAULIC MASTER CYLINDER

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The Master Cylinder in Action

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 Master cylinder with leak

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 Brake system working

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 Brake system working

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 Brake system working

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 Brake system working

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 Brake system working

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 Brake system working

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 Brake system working

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 Brake system working

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 Brake system working

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 Brake system working

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 TECHNICAL SPECIFICATIONS

TANDEM MASTER CYLINDER

TYPE : AS / AS TANDEM FOR NON – ABS

BORE DIA: 26.99 mm

STROKE : 32 mm
(PRIMARY : 18 mm & SECONDARY 14 mm)
CIRCUIT: PRIMARY TO FRONT AND
SECONDARY TO REAR

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 TECHNICAL SPECIFICATIONS

TANDEM MASTER CYLINDER

TYPE : CV / CV TANDEM FOR – ABS

BORE DIA: 26.99 mm

STROKE : 32 mm
(PRIMARY : 18 mm & SECONDARY 14 mm)
CIRCUIT: PRIMARY TO FRONT AND
SECONDARY TO REAR

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 PRODUCT
Disc brake Assembly KNOWLEDGE

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 Advantages of Disc brake
1. Fade Resistance - Air can quickly cool the disc & pads (80 % of the rotor is exposed
to the air,cooling passages cast into them to help reduce operating temperatures) –
lining fade reduced

2. Even, straight stops - The friction of disc brakes is directly proportionally to the
pressure applied. ( In drum brake – self energizing action tends to be uneven side to
side

3. Wet stopping is possible - Water simply runs off the vertical rotor surface and the
pads constantly rub against the rotor surface effectively preventing water buildup
and wet brake fade
Vented disc brakes have a set
of vanes, between the two
sides of the disc, that pumps air
through the disc to provide
cooling.

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 COMPONENTS OFCALIPER BRAKE
The main components of a disc brake are:
The brake pads The caliper, which contains a piston The rotor, which is mounted
to the hub

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 BRA KE N O T A PPLIED CO N D IT IO N

B rake
F lu i d
in le t

H o u s in g

Pad S eal B r a k e F lu i d
P is t o n

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 BRA KE A PPLIED CO N D IT IO N

B rake
F lu i d
i n le t

H o u s in g

Pad S eal B r a k e F lu i d
P is t o n

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 How Disc Brakes Work
Most modern cars have disc brakes on the front wheels, and some have disc
brakes on all four wheels. This is the part of the brake system that does the
actual work of stopping the car.

The most common type of disc brake on modern cars is the single-piston
floating caliper.

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There is also an inspection opening in the caliper so you can
see how much friction material is left on your brake pads.

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TECHNICAL SPECIFICATIONS

CALIPER ASSEMBLY
TYPE : C 45 + 45 COLETTE
(SLIDING CALIPER)

SIZE : TWIN PISTON 45 mm DIA.

DISC DIA 280 mm
DISC THICKNESS : 24 mm

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 IDENTIOFICATION OF PADS

OUTBOARD PADS :
2 SHIMS, 1 VOLVORINE SHIM (BLACK), 1
STEEL SHIM(WHITE).
BLACK SHIM TO BE FITTED WITH
BACKPLATE FIRST.

INBOARD PADS:
1 SHIM, STEEL(WHITE)

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 PRODUCT
Drum brake Assembly KNOWLEDGE

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 DRUM BRAKE

PROVIDES STOPPING FORCE AT

THE ROAD WHEEL, BY PUSHING
THE BRAKE SHOES AGAINST THE
INNER DIAMETER OF THE BRAKE
DRUM.

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 DRUM BRAKES

Drum brake with drum Drum brake without

in place Brake Drum
drum in
place

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 DRUM BRAKE IN OPERATION

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 The Emergency Brake

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BASIC ELEMENTS OF A DRUM BRAKE…

ƒ BACK PLATE / TORQUE PLATE

ƒ ACTUATING MECHANISM
ƒ LINED SHOE (LEADING / TRAILING)
ƒ SHOE RETURN SPRING
ƒ SHOE HOLD DOWN SPRING
ƒ DIRT SHIELD
ƒ PARKING BRAKE MECHANISM

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 BASIC ELEMENTS OF A BRAKE…
WHEEL CYL.
BACK PLATE
LINED SHOE (T)
LINED SHOE (L)
SHOE RETURN
SPRING

SHOE HOLD
DOWN SPRING

ABUTMENT

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Use Genuine TVS Girling Products
TECHNICAL SPECIFICATIONS
REAR BRAKE ASSEMBLY
HASF Leading / Trailing automatic incremental type
adjustment drum brake with Hand Brake attachment.
DIA PASSENGER : 280 X 50.8 mm
DIA PICK-UP : 295 X 60.0 mm
W/CYLINDER ASSEMBLY:
PASSENGER : DIA 25.4 mm C.I. MATERIAL

PICK-UP : DIA 25.4 mm AL MATERIAL.

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 REAR BRAKE
TYPE : HASF (HYDRAULIC AUTO - ADJUST
BY SERVICE BRAKE WITH
FORWARD PULL HAND BRAKE)
SIZE : DIA 282 X 50.80 mm
TYPE OF AUTO ADJUSTMENT : INCREMENTAL
OPERATING CLEARENCE :
BETWEEN LINING : 0.3 mm
& BRAKE DRUM :
WHEEL CYLIDER TYPE : DOUBLE ACTING - CAST IRON
WHEEL CYLINDER
BORE : DIA 25.40 mm

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 PRODUCT
Valve - LSPV KNOWLEDGE

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 Why Valve ?
‰ During Braking - Weight transfers from rear axle to front axle
‰ If braking deceleration exceeds road to tyre adhesion - wheel lock occurs (Wheel stops
spinning & Vehicle moves by inertia)
‰ Front & Rear Wheels Lock
‰ Valves provide better stability under braking
‰ Avoids Rear Wheel Lock which is dangerous

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The LSPV senses the weight on the rear
wheels and adjusts the braking
pressures accordingly, even if by weight
transfer, the alteration occurs during
braking. The valve is fitted in the rear
line and has no effect on the front
brakes. At front circuit failed condition,
rear circuit receives 100% of inlet
pressure.

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Load Sensing Pressure Valve (LSPV)

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LSPV with By-pass (Integral) Installation Layout.

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 Bleeding
• BLEEDING IS REMOVEL OF AIR FROM THE
SYSTEM.
• ENSURE TO BLEED THE SYSTEM PERFECTLY.
• ALWAYS USE THE RECOMMENDED BRAKE FLUID
FOR BLEEDING THE SYSTEM.
• PEDAL SPONGINESS IS THE INDICATION OF
IMPROPER BLEEDING.
• BLEEDING HAS TO BE DONE WHENEVER
HYDRAULIC BRAKE CIRCUIT IS OPENED.
• THE BLEEDING SEQUENCE: FRONT LEFT, FRONT
RIGHT, REAR LEFT AND REAR RIGHT.

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 DO’s
• Always clean the hands before overhauling the brake system.
• Use only brake fluid or alcohol to clean hydraulic cylinders and
calipers during overhauling.
• Use same grade of pads/lined shoes at both LH/RH side
caliper/drum brakes.
• Anti rattle clips on the calipers should be changed at every pad
change.
• Shoe return springs should be replaced at every lined shoe
change.
• Use brake fluid approved by vehicle manufacturer.
• Use only vehicle manufacturer approved brake parts.
• Use transparent bleed bottle & pipe while bleeding.
• Use separate container for brake while dispensing out brake bleeding.

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 DON’Ts
• Never use Kerosene, Petrol and Diesel to clean the brake
system during overhauling.
• Never mix up the different grades of Brake Fluid for topping up
in the system.
• Never allow the friction surface to come in contact with oil or
grease.
• Never use sharp tools/instruments for removal of rubber seals
as it will score the machine surface.
• Do not use the disc below the recommended thickness.
• Do not apply hard braking immediate after replacing with new
pads for the first 20-25 brake application.
• Don’t use drained brake fluid for Topping.Bled brake fluid will have air
bubbles.
• Don’t skim the brake drum beyond the recommended oversize.
• Mineral based grease should not be used to service the Caliper Sliding
Pins.

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 Bleeding

• BLEEDING IS REMOVEL OF AIR FROM THE SYSTEM.

• ENSURE TO BLEED THE SYSTEM PERFECTLY.
• ALWAYS USE THE RECOMMENDED BRAKE FLUID FOR
BLEEDING THE SYSTEM.
• PEDAL SPONGINESS IS THE INDICATION OF IMPROPER
BLEEDING.
• BLEEDING HAS TO BE DONE WHENEVER HYDRAULIC
BRAKE CIRCUIT IS OPENED.
• THE BLEEDING SEQUENCE: FRONT LEFT & REAR RIGHT
AND FRONT RIGHT, REAR LEFT.

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 RECOMMENDATION

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DON’T DISTURB
THE OUTPUT
ROD STAND OUT

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FLUID CONTAMINATION WILL CAUSE THE SEAL SWELL.

DON’T USE KEROSENE, PETROL AND DIESEL TO

OVERHAUL THE HYD. CYLINDERS

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CALIPER ASSEMBLY :

OVERHAUL ONCE IN 2 YEARS OR 40,000 KMS WHICHEVER IS EARLIER.

USE APPROVED GRADE OF GREASE FOR SERVICING THE SLIDING PINS

MINERAL BASED GREASE SHOULD NOT BE USED TO SERVICE THE PINS.

DON’T DISTURB
THE OUTPUT
ROD STAND OUT

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 WHENEVER NEW PADS ARE REPLACED,
REPLACE THE ANTI RATTLE CLIP.

DON’T DISTURB
THE OUTPUT
ROD STAND OUT

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 WHENEVER NEW LINED SHOES ARE REPLACED,
REPLACE THE SPRINGS WITH GENUINE TVS-
GIRLING SPRINGS.

DON’T DISTURB
THE OUTPUT
ROD STAND OUT

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Use Genuine TVS Girling Products
Use Genuine TVS Girling Products
Use Genuine TVS Girling Products
Use Genuine TVS Girling Products
Use Genuine TVS Girling Products
 Maintenance Recommendation

• EVERY WEEK
• BRAKE FLUID LEVEL SHOULD BE CHECKED
EVERY WEEK AND IT SHOULD BE BETWEEN MIN.
AND MAX. MARKINGS IN THE RESERVOIR
• CLEAN THE RESEVOIR CAP BEFORE TOPPING UP
THE BRAKE FLUID.

• BRAKE INSPECTION
• CHECK THE BRAKE LINING FOR WEAR AT EVERY
5,000KMS INTERVEL.

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 Maintenance Recommendation

• EVERY 6MONTHS OR 30,000 KMS

• OVERHAUL THE TANDEM MASTER CYLINDER
AND WHEEL CYLINDER
• REPLACE SHOE RETURN SPRINGS WHENEVER
LINED SHOES ARE REPLACED.
• EVERY YEAR
• BRAKE FLUID SHOULD BE REPLENISHED ONCE IN
EVERY 12 MONTHS

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 Service Limit
• LINING
• DO NOT ALLOW THE LINING TO WEAR UPTO THE SHOE RIM OR
PAD BACK PLATE.
• WHEEL CYLINDER
• IF THE CLEARENCE BETWEEN THE PLUNGER OUTER DIAMETER
AND BORE DIAMETER EXCEEDS 0.25mm THE CYLINDER TO BE
REPLACED.
• MASTER CYLINDER
• IF THE CLEARENCE BETWEEN THE PLUNGER OUTER DIAMETER
AND BORE DIAMETER EXCEEDS 0.20mm THE CYLINDER TO BE
REPLACED.
• HOSES
• TO BE REPLACED ONCE IN TWO YEARS OR IF ANY DAMAGE IS
NOTICED

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 SERVICE LIMIT

DESCRIPTION VALUE
PAD TOTAL THICKNESS 16.40 TO 16.50 mm
PAD USEFUL THICKNESS 10.35 mm
PAD SERVICE LIMIT 6.50 mm
DISC OD 280 mm
DISC THICKNESS 24 mm
DISC SERVICE LIMIT 22 mm
DISC FACE OUT 0.10 mm
REAR LINING SERVICE LIMIT
1.6 mm
ABOVE THE SHOE RIM
MAX. TAPER/BELL MOUNTING
0.05 mm
OF BRAKE DRUM
LSPV SPRING SETTING LENGTH 92.5 mm

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Use Genuine TVS Girling Products