Unit 2

Master Cylinders and

Hydraulic Valves
 Introduction

• Brake units are applied using principles of

hydraulics.
• Pressing down on the brake pedal
– Creates pressure in the brake fluid
– Transmits pressure to the brake units
 Principles of Hydraulics

• Pascal’s law principle behind hydraulic brakes

• Pressure = force per unit area
• The same pressure applied over different-sized
surface areas will produce different levels of
force
 Hydraulic Components (1 of 8)

• Brake fluid has precise amount of braking force

at each wheel.
• Three variables to consider:
– Input force
– Working pressure
– Output force
 Hydraulic Components (2 of 8)

• Brake fluids graded against the United States

Department of Transportation (DOT) standards:
– pH value
– Viscosity
– Resistance to oxidation
– Stability
– Boiling point
Hydraulic Components (3 of 8)
 Hydraulic Components (4 of 8)

• Single-piston master cylinders have one piston

with two cups (seals).
– Primary cup
– Secondary cup
Hydraulic Components (5 of 8)

A single-piston master cylinder with primary and

secondary cups.
Hydraulic Components (6 of 8)

• Recuperation: holes
are drilled into piston
so brake fluid can
pass through inlet
port, preventing
vacuum.
 Hydraulic Components (7 of 8)

• Brake fluid pressure held above atmospheric

pressure by residual pressure valve
– Outlet end of master cylinder in single-piston master
cylinder
– Under tube seats on tandem master cylinder
 Hydraulic Components (8 of 8)

• Tandem cylinder has primary piston and

secondary piston.
 Brake Lines and Hoses (1 of 7)

• Brake lines and hoses carry brake fluid from

master cylinder to brake units.
 Brake Lines and Hoses (2 of 7)
• Brake lines basically
same on all systems and
passenger vehicles
– Double-walled steel
– Coated
– Attach with clips or
brackets
– Better protect them from
corrosion and physical
Flexible brake hose. damage in some vehicles
– Must conform to applicable
standards such as SAE
 Brake Lines and Hoses (3 of 7)
• Inverted double flare
– First flare the end of the
tube outward in a Y-
shape
– About half the flared end
is folded inside itself
(inverted)
– Flare portion of tube is
An inverted double flared line and clamped between mating
matching fitting. surfaces of two fittings
– Provides leak-proof
connection
 Brake Lines and Hoses (4 of 7)

• Brake hose materials made of several layers of

alternating materials
– Inside liner
– Liner wrapped in two or more layers
– Layers covered with tough flexible outer housing
jacket
 Brake Lines and Hoses (5 of 7)

• Brake hoses should never be pinched,

kinked, or bent tighter than specified
radius. Doing so can
– reduce their life
– cause failure of the brake hose
Brake Lines and Hoses (6 of 7)

• Brake hoses use

fittings to connect to
wheel unit.
– Banjo fitting
– Banjo bolt
– Copper/aluminum
washers

Banjo bolt assembly.

 Brake Lines and Hoses (7 of 7)

• Brake hoses need to

be checked
periodically for
damage or defects.
– Cracks
– Bulges
– Abrasion/wear
– Kinks
– Internal deterioration
 Hydraulic Braking
System Control (1 of 4)
• Hydraulic braking system must be controlled
accurately to maintain control of vehicle during
braking.
• Components help maintain control.
– Proportioning valves
– Metering valves
– Pressure differential valves
– Anti-lock HCU
 Hydraulic Braking
System Control (2 of 4)
• Proportioning valves reduce brake pressure
and can be pressure-sensitive or load-sensitive.
– Pressure-sensitive valve in master cylinder
– Load-sensitive valve mounted on body or axle
 Hydraulic Braking
System Control (3 of 4)
• Poppet valve held against retainer by light
return spring.
– During heavy braking, master cylinder pressure can
reach poppet valve’s crack point.
 Hydraulic Braking
System Control (4 of 4)
• Adjustable proportioning valves require a lot of
trial and error to set up properly.
– Not recommended for most applications
Hydraulic Braking Control System

• Combination valve
combines pressure
differential valve,
metering valve, and
proportioning valve(s)
in one unit.
 Hydraulic Braking System Control

• Electronic brake proportioning function reduces

hydraulic pressure to rear wheels under heavy
braking.
– Similar to proportioning valve
– Handled electronically
 Brake Warning Lights
and Stop Lights (1 of 3)
• Red lights are used as warning devices.
• Two general categories:
– Brake warning lights
– Stop lights
 Brake Warning Lights
and Stop Lights (2 of 3)
• Brake warning lights are single lights located in
the instrument panel.
– Warn drivers of conditions in braking system that
need attention.
– Can be illuminated by four causes:
• Parking brake engaged
• Brake fluid too low
• Unequal pressure in brakes
• Prove out or proofing circuit
 Brake Warning Lights
and Stop Lights (3 of 3)
• Stop lights warn others vehicle is braking.
– Mounted on rear of vehicle
– Must conform to federal lights for brightness and
location
• All new passenger vehicles must have a center
high-mount stop lamp (CHMSL).
 Power Brakes (1 of 2)

• Power booster/brake uses external sources of

force to multiply driver’s pedal effort.
• Two main types:
– Vacuum-assisted (most common)
– Hydraulic-assisted
 Power Brakes (2 of 2)

• Vacuum booster chambers separated by

flexible rubber diaphragm attached to
diaphragm plate.
• Dual-diaphragm boosters work on same
principle as single-diaphragm boosters.
 Hydraulic Brake Booster (1 of 2)

• Many vehicles are

now equipped with
hydraulically assisted
brake boosters.
– uses hydraulic
pressure generated by
the power steering
pump rather than
engine vacuum.
• Diesel engines
 Hydraulic Brake Booster (2 of 2)

• Hydraulic pressure generated by power

steering pump.
• Can be completely separate components from
master cylinder or integrated components with
master cylinder
 Electrohydraulic Braking (1 of 3)

• EHB system less

lesson common.
• Replaces booster with
electronically driven
hydraulic pump
• Uses high-pressure
accumulator
 Electrohydraulic Braking (2 of 3)

Common tools used to repair brakes. A. Brake bleeder wrenches.

B. Vacuum brake bleeder. C. Pressure brake bleeder.
D. Proportioning valve/metering valve gauge sets. E. Brake fluid tester.
 Electrohydraulic Braking (3 of 3)

• Brake fluid is the life-blood of hydraulic braking

system.
• To check if it should be flushed:
– Check the time/mileage
– Complete a digital volt-ohmmeter(DVOM)-galvanic
reaction test
– Or a boiling point test
– Or do a test strip
 Summary

• The principle behind hydraulic brakes is

Pascal’s Law, which states that pressure
applied to a fluid in one part of a closed system
will be transmitted without loss to all other areas
of the system.
• A substantial leak in the hydraulic braking
system will prevent enough pressure from
building to exert the necessary braking force.
 Summary

• Engineers design brakes that have precise (but

unequal from front to back) amounts of braking
force at each wheel.
• The three variables related to pressure and
force in hydraulic systems are: input force,
working pressure, and output force.
• Main components of the hydraulic braking
system are: brake pedal, brake fluid, and
master cylinders.
 Summary

• The brake pedal multiplies force from the

driver’s foot to the master cylinder.
• Brake fluid has a high boiling point, a low
freezing point, and is hygroscopic (absorbs
water).
• Brake fluids are graded by the Department of
Transportation on: pH value, viscosity,
resistance to oxidation, stability, and boiling
point.
 Summary

• Master cylinders convert force exerted from the

brake pedal into hydraulic pressure to activate
wheel brake units.
• Types of master cylinders are: single piston and
tandem (required on modern cars).
• Single piston master cylinders use a primary
cup to seal pressure in the cylinder and a
secondary cup to prevent fluid loss.
 Summary

• A single piston master cylinder traps brake fluid

and forces it into the brake lines.
• Residual pressure valves are used on drum
brake systems to maintain brake fluid pressure
and prevent air entry when the brakes are off.
• Modern vehicles have tandem master cylinders
to ensure braking ability in at least one circuit
despite a leak.
 Summary

• Differential pressure switches monitor loss of

pressure between the hydraulic circuits.
• Braking units can be split front-to-rear,
diagonally, or in an L-shape.
• Diagonal and L-shaped braking splits retain
50% braking capability even if half the system
fails.
 Summary

• Quick take-up master cylinders work to

compensate for the large running clearance
maintained by low-drag brake calipers.
• It can be dangerous to add brake fluid without
diagnosing the reason for a low fluid level.
 Credits

• Unless otherwise indicated, all photographs and

illustrations are under copyright of Jones &
Bartlett Learning.