SsangYong Rexton. Manual — part 493
SSANGYONG Y200
4A-2 BRAKE SYSTEM
DESCRIPTION AND OPERATION
BRAKING SYSTEM TESTING
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake
performance cannot be made if the roadway is wet,
greasy or covered with loose dirt which can cause tires
not to grip the road unequally. Testing also will be
inaccurate on a crowned roadway because the wheels
tend to bounce.
Test the brakes at different vehicle speeds with both
light-and heavy-pedal pressure; however, avoid locking
the brakes and sliding the tires. Locked brakes and
sliding tires do not indicate brake efficiency since
heavily braked but turning wheels will stop the vehicle
in less distance than locked brakes. More tire-to-road
friction is present with a heavily braked, turning tire
than with a sliding tire.
There are three major external conditions that affect
brake performance:
•
Tires having unequal contact and grip of the road
will cause unequal braking. Tires must be equally
inflated and the tread pattern of the right and the
left tires must be approximately equal.
•
Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power and thus more braking
effort than the others.
•
Misalignment of the wheels, particularly conditions
of excessive camber and caster, will cause the
brakes to pull to one side.
HYDRAULIC BRAKE SYSTEM
BRAKE PEDAL
YAD4A010
This system uses the principle of the leverage and
PASCAL’s. When you pushes the brake pedal, the
pressure by adapting the pedal increases through the
power booster and delivers it into the master cylinder
to generate hydraulic pressure.
Hydraulic pressure generated by the master cylinder
delivers to the caliper through the brake pipe or hose.
This hydraulic pressure allows the caliper pad to push
the disc plate. Thus it generates the braking forces.
YAD4A020
Brake pedal uses the principle of the leverage and
increases the pressure into the master cylinder in order
to generate the braking forces.
MASTER CYLINDER
The master cylinder is designed for use in a diagonally
split system. One front and one diagonally opposite
rear brakes are served by the primary piston. The
opposite front and rear brakes are served by the
secondary piston.
The master cylinder incorporates the functions of the
standard dual master cylinder, plus a low fluid level
indicator and the proportioning valves in the non-
antilock braking system. The proportioning valves limit
the outlet pressures to the rear brakes after a
predetermined master cylinder pressure has been
reached. The brake master cylinder sensor is attached
under the body of the plastic brake master cylinder
reservoir.
YAD4A030
BRAKE SYSTEM 4A-3
SSANGYONG Y200
YAD4A040
BRAKE BOOSTER
The brake booster is a double-diaphragm, vacuum-
suspended unit. In normal operating mode, with the
service brakes in the release position, a vacuum-
suspended booster operates with a vacuum on both
sides of its diaphragm. When the brakes are applied,
air at atmospheric pressure is admitted to one side of
the diaphragm to provide the power assist. When the
brakes are released, atmospheric air is shut off from
that side of the diaphragm. The air is then drawn from
the booster through the vacuum check valve by the
vacuum source.
1. Pressure Distribution At working
When it pushes the brake pedal, the booster pushrod
(1) pushes the poppet (2) and valve plunger (3) and
the poppet (2) goes closely to the power piston (5)
resulting in closing the vacuum valve (9). The power
cylinder (A) and (B) is isolated and the valve plunger
(3) is separated from the poppet (2). And then the air
valve (6) opens in order to flow air into (B) through the
filter and thus, the power piston (5) enables to push
t h e m a s t e r c y l i n d e r p u s h r o d ( 7 ) f o r p r e s s u r e
distribution.
2. Pressure Distribution After working
When it pushes off the brake pedal, the valve plunger
(3) returns back to the original position by return spring
(4) resulted in closing the air valve (6) and open the
vacuum valve (9) in order to balance the pressures
between (A) and (B) of the power cylinder. And then
the power piston (5) returns back to the original position
by the master cylinder reaction and the diaphragm
return spring (8) pressure.
YAD4A050
SSANGYONG Y200
4A-4 BRAKE SYSTEM
SPECIFICATIONS
Drum Type
←
←
←
←
←
Drum Type
Ø 254
55 x 243
Drum Type
4.3 : 1
138 mm
1 ~ 4 mm
Ø 25.4 mm
7 : 1
Drum Type
Ø 254 mm
55 x 243 x 5 mm
Pedal Ratio
Pedal Stroke
Pedal Freeplay
Inner Diameter
Ratio
Type
I.D of Drum
Lining
Type
Type
Spec.
Application
Brake Pedal
Master Cylinder
Brake Booster
Front Brake
Rear Brake
Parking Brake
Brake Fluid
MANDO Brake
KDAC Brake
Disc Type
←
←
←
←
←
Solid Disc
-
-
Disc Type
-
-
-
←
←
←
-
-
Rear Wheel Internal Expansion
Mechanical
DOT4 or DOT3
Type
Tandem Type
(/W Lever Sensor)
←
←
-
Type
Vacuum Booster
Type
←
←
←
I.D. of Caliper
Cylinder
-
Ø 60 mm
-
Ø 60 mm
Thickness of
Brake Pad
-
10 mm
-
←
Thickness of
Disc Plate
-
24 mm
-
←
Shoe Type
Leading End
Trailing Type
-
Leading End
Trailing Type
-
I.D. of Wheel
Cylinder
Ø 23.87 mm
-
Ø 23.81 mm
-
I.D. of Caliper
Cylinder
-
Ø 42.9 mm
-
Ø 42 mm
Thickness of
Brake Pad
-
10 mm
-
10 mm
Thickness of
Disc Plate
-
10.4 mm
-
10.4 mm
Type
-
Ventilated
Disc Type
-
←
BRAKE SYSTEM 4A-5
SSANGYONG Y200
Repair
Retighten
Replace
Clean
Replace
Repair
Repair
Lubrication
Retighten
Adjust
Repair
Replace
Replace
Repair
Repair
Replenish or Replace
Bleeding
Repair
Repair
Replace
Repair
Repair
Repair
Repair
Bleeding
Repair
Adjust
Repair
Adjust
Replace
Repair
Replace
Lubrication
Replace
Adjust
Replace
Replace
Replace
Repair
Adjust Lever Travel or
Check the Cable
Incorrectly Mounted Back Plate or Caliper
Loosened Bolt of Back Plate or Caliper
Crack or Uneven Wear of Brake Drum or Disc
Foreign Material Inside the Brake Drum
Pad or Lining Sticking to Contact Surface
Excessive Clearance Between Caliper and Pad
Uneven Contact of Pad
Lack of Lubrication
Loosened Suspension
Incorrect Tire Pressure Between Left and Right
Poor Contact of Pad or Lining
Oil or Grease is Applied to Pad or Lining
Bent or Uneven Wear of Drum
Incorrectly Mounted Wheel Cylinder
Faulty Auto Adjuster
Dirty or Lack of Fluid
Air in Brake System
Faulty Brake Booster
Poor Contact of Pad or Lining
Oil or Grease on Pad
Faulty Auto Adjuster
Over Heated Rotor Due to Dragging Pad or Lining
Clogging Brake Line
Faulty Proportioning Valve
Air in Brake System
Fluid Leaking
Excessive Clearance Between Push Rod and M/Cylinder
Parking Brake is not Fully Released
Incorrect Adjustment of Parking Brake
Weak Return Spring of Brake Pedal
Incorrect Pedal Free-play
Broken Rear Drum Brake Shoe Return Spring
Lack of Lubrication
Damaged Master Cylinder Check Valve or Piston
Return Spring
Insufficient Clearance Between Push Rod and Master
Cylinder
Worn Brake Lining
Dirty Brake Lining Surface by Grease or Oil
Binding Parking Brake Cable
Faulty Auto Adjuster
Excessive Lever Stroke
Noise Or Vehicle Vibration
When Applied Brake
DIAGNOSTIC INFORMATION AND PROCEDURES
Symptom
Check
Action
Pulls To One Side When
Braking
Poor Braking
Increasing Pedal Stroke
(Pedal Goes To Floor)
Brake Dragging
Poor Parking Brake
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