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PEMERINTAH KOTA SUKABUMI

DINAS PENDIDIKAN DAN KEBUDAYAAN


SEKOLAH MENENGAH KEJURUAN NEGERI 1SUKABUMI
Jl. Kabandungan No. 90 Telp.(0266) 222305 Fax (0266)233552 Sukabumi 43113
Website http://www.smkn1-smi.org email: info@smkn1_smi@lycos.com

BRAKE

SYSTEM

AUTOMOTIVE DEPARTMENT
2008
PREFACE

Module is compiled to use training system being based on interest to teach skill at
work. Training pursuant to interest standard that is a way of which nationally have been
agreed on about forwarding of skill, knowledge and attitude used for the duty of certain
work with especial emphasis at aspect what can be conducted by someone as result of in
following network activity of training. One of the important characteristic about training base
on interest is emphasis at training have the character of individually for the work of actual at
work.
This module can be used by participant of training and education and also instructor /
instructor to give study activity at participant of training and education relate to interest unit
according to Mechanic interest standard of Automotive with interest unit title "Brake System"
which comprising skill and knowledge for the work of to repair.
In general fill this module consider fully the condition of training of organization and
skill management of adapted for by training and education requirement of industry without
there is diffraction at individual sector, to support mentioned, this module will be considered
the followings :
 Requirement of participant of training and education
 Conditions of organization
 Time which available to conducting training and education
 Training situation.
Strategy of forwarding of which is used and assessment techniques which is
presented in this interest unit module is not have the character of obliged to but
representing minimum prerequisite which must be used as by guidance of usage of module.
Consumer of this module is pushed to use various experience learn previously covering
knowledge, skill and also experiences learn the other to develop knowledge and skill which
included in this module and also so that can ascertain relevansi activity of training and
education with requirement of work in industry.

Compiler

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TABLE OF CONTENTS
PAGE

PREFACE …………………………………………………………………………………… i
TABLE OF CONTENTS………………………………………………………………………………………
ii
MAP DOMICILE MODULE ………………………………………………………………… iii
GLOSSARIUM ..............……………………………………………………………… iv

ANTECEDENT ………………………………………………………………………………
A. DESCRIPTION …………………………………………………………………………
B. SUB-TERMS ……………………………………………………………………………………
C. MODULE USING GUIDANCE ……………………………………………………
D. ULTIMATE PURPOSES ………………………………………………………………………………
E. COMPETENSI …………………………………………………………………………………
F. CHECKING ABLITY…………………………………………………………………………

LESSON ……………………………………………………………………………………..
A. PLAN LEARN STUDENT…………………………………………………………
B. ACTIVITY LEARN………………………………………………………………………
1. Activity Learn 1 : Brake System …………………………..
a. Target Activity Learn 1 ……………………………………………….
b. Theory 1 …………………………………………………………………
c. Ambit 1 ……………………………………………………………………..
d. Duty1 ……………………………………………………………………….
e. Formative Test 1 ……………………………………………………………………
f. Formative answer key 1 ……………………………………………
g. Sheet Assessment 1 ………………………………………………….
EVALUATION ………………………………………………………………………………………
A. KNOWLEDGE TEST …………………………………………………………………………………
B. ANSWER TEST ……………………………………………………………………………
C. ASSESSMENT EVALUATION………………………………………………….
D. CRITERION PASS ……………………………………………………………………

CONCLUSION…………………………………………………………………………………

BIBLIOGRAPHY…………………………………………………………………………………

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 MAP DOMICILE MODULE
OPKR40-016B

OPKR 30-007B OPKR 40-014B

OPKR 30-017B OPKR 40-009B OPKR 50-019B

OPKR 20-010B OPKR 40-004B OPKR 50-011B


OPKR 30-010B

OPKR 20-012B OPKR 30-003B OPKR 40-003B OPKR 50-008B

OPKR 30-013B

OPKR 30-004B

OPKR 30-002B OPKR 40-002B OPKR 50-009B

OPKR 20-001B OPKR 20-017B OPKR 30-001B OPKR 40-001B OPKR 50-007B

OPKR 20-010B OPKR 20-014B OPKR 10-018B OPKR 40-008B OPKR 40-012B OPKR 50-002B

OPKR 10-006B OPKR 10-003B

OPKR 10-017B
OPKR 10-005B OPKR 10-001B OPKR 10-002B

OPKR 10-015B OPKR 10-010B OPKR 10-009B OPKR 10-019B OPKR 40-017B OPKR 40-019B

OPKR 50-001B

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 LIST TITLE MODULE.
No KODE Judul Modul
1 OPKR 10-001B Execution of conservancy/ component service (Pelaksanaan pemeliharaan/ servis
komponen)
2 OPKR 10-002B Installation of hydraulic system (Pemasangan sistem hidrolik)
3 OPKR 10-003B Conservancy / hydraulic system service (Pemeliharaan/servis sistem hidrolik)
4 OPKR 10-005B Conservancy / service and repair of air compressor and components (Pemeliharaan/servis
dan perbaikan kompresor udara dan komponen-komponennya)
5 OPKR 10-006B Execute procedure of welding, soldering, and amputation with heat and warm-up
(Melaksanakan prosedur pengelasan, pematrian, dan pemotongan dengan panas dan
pemanasan)
6 OPKR 10-009B Read and understanding of technique picture (Pembacaan dan pemahaman gambar
teknik)
7 OPKR 10-010B Usage and conservancy of measuring instrument (Penggunaan dan pemeliharaan alat
ukur)
8 OPKR 10-016B Follow health procedure and Usage working safety (Mengikuti prosedur kesehatan dan
keselamatan kerja)
9 OPKR 10-017B Usage and conservancy of equipments and supply of workplace (Penggunaan dan
pemeliharaan peralatan dan perlengkapan tempat kerja)
10 OPKR 10-018B Constribution communications at work (Konstribusi komunikasi di tempat kerja)
11 OPKR 10-019B Execution of handling operation manually (Pelaksanaan operasi penanganan secara
manual)
12 OPKR 20-001B Conservancy / service engine and components (Pemeliharaan/servis engine dan
komponen-komponennya)
13 OPKR 20-010B Conservancy / cooler system service and components (Pemeliharaan/servis sistem
pendingin dan komponen-komponennya)
14 OPKR 20-011B Repair of cooler system and components (Perbaikan sistem pendingin dan komponen-
komponennya)
15 OPKR 20-012B Overhaul Component cooler system (Overhaul komponen sistem pendingin)
16 OPKR 20-014B Conservancy/service gasoline fuel system (Pemeliharaan/servis sistem bahan bakar
bensin)
[of] /
17 OPKR 20-017B Conservancy/ service diesel fuel system (Pemeliharaan/servis sistem injeksi bahan bakar
diesel)
18 OPKR 30-001B service clutch and system operation components ( Pemeliharaan/servis kopling dan
komponen-komponennya sistem pengoperasian)
19 OPKR 30-002B Repair of clutch and components (Perbaikan kopling dan komponen-komponennya)
20 OPKR 30-003B Clutch Overhaul and components (Overhaul kopling dan komponen-komponennya)
21 OPKR 30-004B Conservancy/service manual transmission (Pemeliharaan/servis transmisi manual)
22 OPKR 30-007B Conservancy/ service automatic transmission (Pemeliharaan/servis transmisi otomatis)
23 OPKR 30-010B Conservancy/ service final unit drive/ differential (Pemeliharaan/servis unit final drive/
gardan)
24 OPKR 30-013B Conservancy / service wheel axis activator (Pemeliharaan/servis poros roda penggerak)
25 OPKR 30-014B Repair of wheel countershaft (Perbaikan poros penggerak roda)
26 OPKR 40-001B Assembling and installation of system put on the brakes and its components (Perakitan
dan pemasangan sistem rem dan komponen-komponennya)
27 OPKR 40-002B Conservancy / system service put on the brakes (Pemeliharaan/servis sistem rem)
28 OPKR 40-003B Repair of system put on the brakes (Perbaikan sistem rem)
29 OPKR 40-004B Overhaul system component put on the brakes (Overhaul komponen sistem rem)
30 OPKR 40-008B Inspection of system drive (Pemeriksaan sistem kemudi)
31 OPKR 40-009B Repair of system drive (Perbaikan sistem kemudi)
32 OPKR 40-012B Inspection of system of suspensi (Pemeriksaan sistem suspensi)
33 OPKR 40-014B Conservancy / system service of suspensi (Pemeliharaan/servis sistem suspensi)
34 OPKR 40-016B Balans wheel / Free tire (Balans roda/ban)
35 OPKR 40-017B (installing and tuning wheel) Melepas, memasang dan menyetel roda
36 OPKR 40-019B Unloading, repair, and installation of external tire and inner tube and also its component (
Pembongkaran, perbaikan, dan pemasangan ban luar dan ban dalam serta komponennya)
37 OPKR 50-001B Examination, conservancy / service and replacement of light Repair battery (Pengujian,
pemeliharaan/servis dan penggantian baterai)

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No KODE Judul Modul
38 OPKR 50-002B Repair network/ system electric (Perbaikan ringan pada rangkaian/ system kelistrikan)
39 OPKR 50-007B Installation, examination, and repair of lighting system and of wiring
(Pemasangan, pengujian, dan perbaikan sistem penerangan dan wiring)
40 OPKR 50-008B Installation, examination, and repair of peacemaker electric system
(Pemasangan, pengujian, dan perbaikan sistem pengaman ke listrikan )
41 OPKR 50-009B Installation of equipment of electric of addition ( assesoris) (Pemasangan kelengkapan
kelistrikan tambahan) (assesoris)
42 OPKR 50-011B Repair of Ignition system (Perbaikan sistem Pengapian)
43 OPKR 50-019B Service system of AC ( Memelihara/servis sistem AC) (Air Conditioner)

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CHAPTER 1
A. Description
Learning this lesson, our students are required to master both the basic
concepts and theories of Brake system. The following are the sub
competencies:
1. Following the procedures at the work place to identify the
functions and basic concepts about Brake system.
2. Students should be able to explain Regenerative Brake Cooperative
Control .
3. Students should be able to describe Brake ECU.
4. Students should be able to describe Skid Control ECU.
5. Students should be able to describe Enhanced VSC system .
6. Students should be able to describe Enhanced VSC operation
B. Sub-terms
This module is basic the knowledge, so the terms are not based on the
previous modules but it requires students knowledge themselves. For
instance:
1. Work principles of mechanic energy and electric energy from their
physic.
2. Attitude: work concentration, discipline to words the rules, etc.
C. Module Using Guidance
1. For Students
To get maximum learning result, in learning this lesson, students
should follow these steps to use this module:
- Read and understand properly the materials on the learning
process.
- Do every assignments to know how far the students understand the
material for each learning activity.
- In doing not only theoritical but also practical, pay attention to
these rules:

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Pay attention to the directions of safety rules.
Understands every procedures of practice.
Before doing the practice, identify the tools and material
needed precisely.
Use the proper tool for each procedures.
To do unclear practice procedures, students should ask the tutor
or instructor.
After students finish practicing, put the tools back to their
places.
- If the students don’t get the skills required (fail to get the skill),
repeat all the process by asking the tutor/ instructor.
2. Teacher Roles
Teacher roles for each learning process are:
- Helping students in preparing and planning the learning process.
- Guide the students through giving practice duties which explained
in each process.
- Helping students to decide and acces additional sources.
- Organizing team work if necessary.
- Planning to bring an expert or a teacher/ tutor from an industry to
accompany the teacher if necessary.
D. Ultimate Purposes
After learning all the materials in this module, students shoul be able to:
1. Apply the safety rules, work and environment healty guidance at
their workplaces.
2. Mention the functions Brake system.
3. Explain the functions Regenerative Brake Cooperative Control.
4. Describe the functions Brake ECU
5. Describe Skid Control ECU.
6. Describe Enhanced VSC system .
7. Describe Enhanced VSC operation

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CHAPTER II
BRAKE SYSTEM
Overview
The hybrid vehicle brake system includes both standard hydraulic brakes
and a unique regenerative braking system that uses the vehicle's momentum to
recharge the battery. As soon as the accelerator pedal is released, the HV ECU
initiates regenerative braking. MG2 is turned by the wheels and used as a
generator to recharge the batteries. During this phase of braking, the hydraulic
brakes are not used. When more rapid deceleration is required, the hydraulic
brakes are activated to provide additional stopping power. To increase energy
efficiency the system uses the regenerative brakes whenever possible. Selecting
•B" on the shift lever will maximize regenerative efficiency and is useful for
controlling speeds downhill. In `B' mode about 30% of the energy is recovered.
If either the regenerative or hydraulic braking system fails, the remaining
system will still work. However, the brake pedal will be harder to press and the
stopping distance will be longer. In this situation, the brake system warning light
will illuminate.

NOTE
The battery will accept charge up to an instantaneous rate of 20 to 21 KWH.
Much of the energy from light braking at high speeds and harder braking at lower
speeds can be recovered. Excess energy over the charging limits is wasted as heat
in the brakes just as in other cars. At this time there is no way for the customer to
know the limit of regenerative energy recovery.
Brake System Components

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Regenerative Brake Cooperative Control
Regenerative brake cooperative control balances the brake force of the
regenerative and hydraulic brakes to minimize the amount of kinetic energy lost to
heat and friction. It recovers the energy by converting it into electrical energy.
To convert kinetic energy to electrical energy the system uses MG2 as a
generator. The drive axle and MG2 are joined mechanically. When the drive
wheels rotate MG2 it tends to resist the rotation of the wheels, providing both
electrical energy and the brake force needed to slow the vehicle. The greater the
battery charging amperage, the greater the resistance.
On the '04 & later Prius, the increased power output of MG2 provides
increased regenerative brake force. In addition, the distribution of the brake force
has been improved through the adoption of the Electronically Controlled Brake
(ECB) system, effectively increasing the range of the regenerative brake. These
attributes enhance the system's ability to recover electrical energy which
contributes to fuel economy.
Regenerative Brake System

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Brake ECU
The Brake ECU communicates with the HV ECU based on signals
received from sensors. The controls include:
Conventional brake control
ABS with EBD control
Regenerative brake cooperative control

Skid Control ECU


Brake control processing is moved to the Skid Control ECU which
maintains communication with the EPS ECU and the HV ECU based on signals
received from sensors. The controls include:
Conventional brake control
ABS with EBD control
Brake Assist
Enhanced VSC
Regenerative brake cooperative control

Enhanced VSC System


The Enhanced VSC system is available on the '04 & later Prius. The
following are two examples that can be considered as circumstances in which tires
exceed their lateral grip limit. The Enhanced VSC system is designed to help
control the vehicle behavior by controlling the motive force and the brakes at each
wheel when the vehicle is meets one of these two conditions:
When the front wheels lose grip in relation to the rear wheels (front wheel
skid tendency known as `understeer')
When the rear wheels lose grip in relation to the front wheels (rear wheel
skid tendency, or `oversteer')

Enhanced VSC Operation


When the skid control ECU determines that the vehicle exhibits a tendency
to understeer or oversteer, it decreases the engine output and applies the brake of a

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front or rear wheel to control the vehicle's yaw moment. The basic operation of
the Enhanced VSC is described below. However, the control method differs
depending on the vehicle's characteristics and driving conditions.
When the skid control ECU determines that there is a large front wheel
skid tendency, it counteracts in accordance with the extent of that tendency. The
skid control ECU controls the motive power output and applies the brakes of the
front wheel of the outer circle in the turns and rear wheels in order to restrain the
front wheel skid tendency.
When the skid control ECU determines that there is a large rear wheel skid
tendency, it counteracts in accordance with the extent of that tendency. It applies
the brakes of the front wheel of the outer circle of the turn and generates an
outward moment of inertia in the vehicle, in order to restrain the rear wheel
tendency. Along with the reduction in the vehicle speed caused by the braking
force, the vehicle's stability is ensured. In some cases the skid control ECU
applies the brake of the rear wheels, as necessary.

Cooperative Control with EPS


Enhanced VSC provides the steering assist to facilitate steering operation
for the driver depending on vehicle situations. This is accomplished through
coordination of cooperative control with EPS in addition to the general VSC
control.

Cooperative Control with EPS

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Brake Pedal Stroke Sensor
This sensor contains a contact variable resistor and detects the extent of
the brake pedal stroke and transmits it to the skid control ECU.

SERVICE TIP
To install a brake pedal stroke sensor, which is available as a service part,
perform the following procedures:
The sensor lever is secured with a pin to •0" stroke. (Do not detach the
pin until the installation has been completed.)
In this state, install the sensor on the brake pedal (in the OFF state) on the
vehicle.
After completing the installation, firmly press the brake pedal once to
break off the pin that is securing the sensor in place.
Make sure the broken pin does not remain in the sensor lever.

Stroke Simulator
The stroke simulator is located between the master cylinder and the brake
actuator. It generates a pedal stroke in accordance with the driver's pedal effort
during braking. Containing two types of coil springs with different spring
constants, the stroke simulator provides pedal stroke characteristics in two stages
in relation to the master cylinder pressure.

Stroke Simulator

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Power Source Backup Unit
In the '04 & later Prius, the power source backup unit has been adopted as
an auxiliary power source in order to supply power to the brake in a stable
manner. This unit contains 28 capacitor cells, which store an electrical charge
provided by the (12V) vehicle power supply. When the voltage of the (12V)
vehicle power supply drops, the electrical charge stored in the capacitor cells is
used as an auxiliary power supply to the brake system. The electrical charge
stored in the capacitor cells becomes discharged when the HV system stops
operating after the power switch is turned OFF.

Power Source Backup Unit

Fail-Safe
If the ABS, Enhanced VSC or Brake Assist System malfunctions, the Skid
Control ECU disables that system but allows the other systems to function
normally.

DRC C1215/15, C1216/16 Linear Solenoid Positive Voltage Malfunction


DTC C1215/15 may be detected when the ignition switch is ON, the
voltage of terminal +BS in the brake ECU is 2.5V or less, and continues for 0.5

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seconds or more. It also may be detected while a vehicle is driven at a speed
5 mph or more, the voltage of terminal +BS in the brake ECU is 9V or less and
continues for 10 seconds or more.
DTC C1216/16 may be detected when the ignition switch is ON, the
voltage of the terminal +BS in the brake ECU is 17V or more, and continues for
1.2 seconds or more. For both codes check the battery, the charging system and
the power source circuit. The trouble areas for both codes may include the battery,
the charging system or the power source circuit.

DTC C1259/59 Malfunction In HV ECU


If any trouble occurs in the HV control system, the ECU prohibits
Regenerative Braking System (RBS) control. If the conditions below continue for
0.02 seconds DTC C1259/59 will set:

The voltage of the terminal IG2 in the brake ECU is 10.5V or less and
continues for 1.5 seconds.
Regenerative malfunction occurs on the HV ECU side.

NOTE
This DTC is set with most HV ECU codes and is usually the lowest priority when
sent with other DTCs.

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CHAPTER III
EVALUATION
A. ASSESSMENT INSTRUMENT

1. Mentioning components of Brake System!


2. Describe about Regenerative Brake Cooperative Control!
3. Describe about Brake ECU!
4. Mentioning function of Skid control ECU!
5. Mentioning function of Enhanced VSC System!
6. Mentioning function of Enhanced VSC Operation!

B. ANSWER KEY

1. Component Barke system:

2. Regenerative brake cooperative control balances the brake force of the


regenerative and hydraulic brakes to minimize the amount of kinetic energy lost
to heat and friction. It recovers the energy by converting it into electrical energy
3. Brake ECU : The Brake ECU communicates with the HV ECU based on signals
received from sensors. The controls include:
 Conventional brake control
 ABS with EBD control
 Regenerative brake cooperative control
4. Skid Control ECU : Brake control processing is moved to the Skid Control ECU
which maintains communication with the EPS ECU and the HV ECU based on
signals received from sensors
5. Enhanced VSC System : The Enhanced VSC system is available on the '04 &
later Prius. The following are two examples that can be considered as
circumstances in which tires exceed their lateral grip limit. The Enhanced VSC
system is designed to help control the vehicle behavior by controlling the motive
force and the brakes at each wheel when the vehicle
6. Enhanced VSC Operation : When the skid control ECU determines that the
vehicle exhibits a tendency to understeer or oversteer, it decreases the engine
output and applies the brake of a front or rear wheel to control the vehicle's yaw
moment. The basic operation of the Enhanced VSC is described below. However,
the control method differs depending on the vehicle's characteristics and driving
conditions.

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C. CRITERION PASS.
Aspect Score (1- wight Value Boldness
10)
Correctness 2 Condition pass,
Accuracy 1 minimum value
70 with score
Time 1 each; every
minimum
Total Score aspect 7.
Pass category :
70 s.d. 79 : fulfilling minimum criterion with tuition
80 s.d. 89 : fulfilling minimum criterion without tuition
90 s.d. 100 : above minimizing without tuition.

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CHAPTER IV
CONCLUSION

Interest of "Brake System" have to well posted by before studying bases


of automotive.
After student feel to master existing interest sub, student can request
interest test, interest test done/conducted by theoritical and practical. Theoretical
test by student answer question which is on evaluation problem, while test of
practical with interest to demonstration had at teacher / instructor. Teacher /
instructor will assess pursuant to existing observation sheet, from here student
interest can know.
To student which have reached minimum pass condition can continue to
next module, but if/when minimum condition of pass not yet been reached hence
have to repeat this module, or part of which do not pass and because do not be
allowed to take next module.

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