Cebu Technological University – Main Campus

M.J. Cuenco Ave, Cor R. Palma Street, 6000 Cebu

Department of Mechanical Engineering

HYDRAULIC BRAKES

Submitted by:
Balorio, Roldan
Paraiso, Louis Ian
Repayo, James Louie

BSME IV-B

Submitted to:

A.A.V. SABERON
Course Professor

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 TABLE OF CONTENTS

Contents
I. INTRODUCTION.......................................................................................................................................................3
II. OBJECTIVES..............................................................................................................................................................4
III. ABOUT THE EQUIPMENT OR SYSTEM..................................................................................................................4
A. DESCRIPTION:......................................................................................................................................................4
B. PARTS:................................................................................................................................................................. 4
C. TYPES................................................................................................................................................................... 5
D. HYDRAULIC BRAKE SYSTEM WARNING LIGHT.....................................................................................................7
IV. FREQUENTLY ASKED QUESTIONS (FAQs) ABOUT HYDRAULIC BRAKE..................................................................8
V. COMMON ISSUES/PROBLEMS/FAILURE..................................................................................................................9
A. AIR CONTAMINATION..........................................................................................................................................9
B. BRAKE SEIZURE....................................................................................................................................................9
C. LEAKAGE..............................................................................................................................................................9
D. BURNT DISC PLATE..............................................................................................................................................9
E. HUMAN ERROR....................................................................................................................................................9
VI. ROOT CAUSE ANALYSIS......................................................................................................................................10
A. Why is there contamination in the medium?....................................................................................................10
B. When will brake seizure occur?.........................................................................................................................10
C. When does leak happen?..................................................................................................................................10
VII. TROUBLESHOOT AND REPAIR METHODOLOGY.................................................................................................11
VIII. SUPPORTING VIDEOS.........................................................................................................................................11
IX. REFERENCES......................................................................................................................................................12

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I. INTRODUCTION

Prior to the adoption of rubber tires in the 1890s, brakes were wooden blocks activated
by a lever which pressed against wheels. This was fine for horse-drawn and steam
powered vehicles which ran steel-rimmed wheels. After the adoption of rubber tires,
wooden block brakes became obsolete as the wood would wear down the rubber.
The next significant progress was the development of the mechanical drum brake, in
1902 by Louis Renault. These brakes were a huge step up on the previous systems, but
as car engines became more powerful, the need for more powerful braking systems
increased. It was Malcolm Loughead (later Lockheed) in 1918 who first examined the
possibility of using hydraulics to increase the braking force that could be applied. Over
the past century these systems have been developed and refined into the modern
hydraulic braking system, but still rely on the fundamental concepts of Loughead’s
system.
A hydraulic system is an efficient transmitter of power for many reasons. Firstly, its
simple levers and push buttons make it easy to start, stop, accelerate and decelerate.
This also allows for control accuracy. Also, because it is such a fluid system, without any
cumbersome gears, pulleys or levers, it easily copes with a huge weight range. It
provides a constant force, regardless of changes in speed. For the most part, hydraulic
systems are simple, safe and economical because they use fewer moving parts
compared to mechanical and electrical systems, which makes them easier to maintain.
Hydraulic systems are safe to use in chemical plants and mines because they do not
cause sparks

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11.2022 – HYDRAULIC BRAKES [Balorio, Paraiso, Repayo]
II. OBJECTIVES
At the end of this discussion, we will be able to;

A. Discuss the functions and importance of hydraulic brakes.

B. Understand the troubleshooting fundamentals of the most common hydraulic brake
problems or issues.
C. Know the importance of proper hydraulic brake maintenance.

III. ABOUT THE EQUIPMENT OR SYSTEM

A. DESCRIPTION: A hydraulic brake is a set up for a braking mechanism that transfers

pressure from the controlling mechanism to the braking mechanism using brake fluid.
Hydraulic brakes transfer energy to stop an object, normally a rotating axle. In a very
simple brake system, with just two cylinders and a disc brake, the cylinders could be
connected via tubes, with a piston inside the cylinders. The cylinders and tubes are filled
with incompressible oil.
B. PARTS:
1. Brake pedal or lever - pedal that you press with your foot in order to make a
vehicle go slower or stop.
2. Master Cylinder - also known as the master brake cylinder, converts the pressure
on the brake pedal to hydraulic pressure by feeding brake fluid into the brake
circuit and controlling this according to the mechanical force
3. Brake Assembly - to stop or slow down the moving motor vehicle or prevent it
from moving when in stationary position.
4. Brake lines and hoses – Brake lines allows your car to turn pedal pressure into
stopping power. Break hoses carry brake fluid from a brake line fixed to the car's
body the rest of the way to the brake caliper on the wheel.
5. Hydraulic brake fluid reservoir - stores your vehicle's brake fluid and protects it so
that your hydraulic braking system can work properly.

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C. TYPES: Energy can be removed by a brake in several ways. Here are some different
approaches to braking:

a. Band - band brakes are the simplest type of brake. They have a metal band lined
with heat- and wear-resistant friction material.

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b. Drum - drum brakes press
shoes against a spinning
surface. They are often

used on automobile rear wheels.

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c. Disc - disc brakes have brake pads, a caliper, and a rotor. During operation, the
brake pads are squeezed against the rotor. Disc brakes have good heat
dissipation properties.

d. Brake for conveyor system- electro-hydraulic drum brakes are widely used in the
deceleration and braking of various mechanisms in various lifting and
transportation, belt transportation, and construction machinery.

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D. HYDRAULIC BRAKE SYSTEM WARNING LIGHT
Brake Hydraulic System Warning Light
If these lights go off and on repeated or when you turn, it can mean to check the brake
fluid level in the master cylinder.

Brake Pad Warning Light

This light is a warning that brake pads are getting too worn and should be replaced
soon.

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 Parking Brake/Hand-Brake Warning Light
This brake light indicates that there is an issue with your parking brake, or it is still
engaged.

IV. FREQUENTLY ASKED QUESTIONS (FAQs) ABOUT HYDRAULIC BRAKE

A. Are discs better than drum brakes?

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B. Why don’t we use hydraulic brakes on trucks?
C. What does bleeding mean?
D. How long do brake pads/shoes last?

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V. COMMON ISSUES/PROBLEMS/FAILURE

A. AIR CONTAMINATION
Air contamination is the entrance of air into a hydraulic system. A contaminant is defined
as anything that impairs the performance of the hydraulic system and its components.
Contamination is also a common problem in hydraulic systems, often caused by system
leaks or condensation due to temperature changes. A milky appearance in hydraulic fluid
can help you identify water contamination.

B. BRAKE SEIZURE
Seizing will occur when your vehicle is not in frequent use. The main reason for this is
because when you brake, the moisture on your discs is usually cleared away. Generally,
you can tell when your brake calipers need replacing when you notice that your brake
pads have worn down excessively. Worn down brake pads will lead to damages on your
disc brakes. A seized brake also makes the brake pad or disc damaged and creates
stress on the transmission. When you will start the car with seized brakes, it will feel like
the brake is active and it is stopping you! In the worst cases, the car cannot move at all.

C. LEAKAGE
Leaking is problematic in that they can allow air to get into the system when the brakes
are released. Air, unlike brake fluid, is compressible, and can result in a spongy feeling
behind the brake pedal, which means the brake pedal has to move farther before the
brakes will be applied.

D. BURNT DISC PLATE

The main cause of burnt disc plate is friction. While the working principle of the braking
system is based on friction, with the aggressive driving style it increases. Besides, the
overheating can be caused by:
• the brake mechanism failure
• incorrect brake pad installation
• usage of brake discs and pads after the expiry of their service life
• low quality of brake discs and pads

E. HUMAN ERROR
Human error is the base cause of many hydraulic system problems. Some of the most
common errors that may result in your hydraulic pump not building pressure include the
following.

A. Faulty installations: Improper installation of any component in a hydraulic system

can result in severe errors.
B. Incompatible parts: An inexperienced installer may put mismatched components
together, resulting in functional failures.
C. Improper maintenance or usage: Using systems outside their operational
capabilities or failing to perform regular maintenance are some of the most
common causes of hydraulic system damage, but are easy to rectify through
updated maintenance policies and training.

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VI. ROOT CAUSE ANALYSIS

A. Why is there contamination in the medium?

Hydraulic fluid contamination is the number one cause of hydraulic system failure and as
such it’s a serious concern for maintenance managers everywhere. Hydraulic systems
can become contaminated in a number of ways - including poor system design, lack of
maintenance or improper maintenance procedures and other contributing factors.
Raising awareness of the consequences of excessive fluid contamination can play a vital
role in achieving reliable hydraulic system performance. Some causes of contamination
include:
1. contamination due to poor quality hoses and fittings.
2. contamination when replacing system components or hydraulic fluid.
3. contamination due to damaged or worn cylinder seals.

B. When will brake seizure occur?

Seizure is a common problem for automobiles that have been sitting idle for a while. The
main cause of brake seizures is corrosion. The brake discs can develop rust which can
lead to the brake pads getting stuck. Because brakes are exposed to the elements and
experience a wide range of temperatures, they are prone to corrosion. They are also
elements which are rarely serviced or examined outside of brake pad replacements.

It frequently happens that moving the automobile can release the brakes, depending on
the severity of the seizure. To do this safely, start your car, then alternate between
driving forward and backward. Your car could feel like it has brakes on and may not
move in either direction, but if you keep moving, the brakes should release. The brakes
can also be released by applying and releasing them repeatedly.

Driving your car once it has been released from the brakes' hold could help reduce the
corrosion since the brake pads do some of their own cleaning while being used. This
should go away on its own, but if it does, you might need to schedule an appointment to
have your brakes thoroughly inspected and cleaned.

C. When does leak happen?

Leaks are generally the result of a breakdown in the segment of the system carrying the
fluid from the place where pressure is applied to the place where it is distributed: in other
words, the connection points for the tubes that carry it. Connections between pipes and
other elements may come loosened as a result of the system's continuous vibration.
Cracks in the pipes can also be brought on by wear and strain. Over time, seals in
hydraulic cylinders may wear out and permit fluid to seep out.

After identifying a leak, the next step is to pinpoint it. Depressurize the system and check
all the connectors, joints, and seals while wearing gloves for small hydraulic systems. A

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 simple tightening of the fittings or connections can stop leaks. Damaged seals and
hoses may need to be replaced.

VII. TROUBLESHOOT AND REPAIR METHODOLOGY

A. Immediate

B. Long Term

VIII. SUPPORTING VIDEOS

https://www.youtube.com/watch?v=_imyybhZV80

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IX. REFERENCES

https://powerbrakes.com/power-brake-troubleshooting-help/
https://en.wikipedia.org/wiki/Hydraulic_brake
https://www.globalspec.com/learnmore/motion_controls/clutches_brakes/hydraulic_brakes
https://www.oponeo.co.uk/blog/hydraulic-brakes
https://www.cerka.ca/troubleshoot-hydraulic-brakes
https://www.abebrakes.com/en/knowledge/the-history-of-braking-systems/
https://sciencing.com/advantages-disadvantages-hydraulic-systems-7198601.html
https://yorkpmh.com/resources/common-hydraulic-system-problems/
https://www.autoscopecarcare.com/the-basics/what-does-brake-warning-light-mean/
#:~:text=Brake%20Hydraulic%20System%20Warning%20Light,suggest%20a%20more
%20persistent%20issue.
https://blog.berendsen.com.au/7-causes-of-hydraulic-fluid-contamination-you-may-not-have-
thought-of#:~:text=Hydraulic%20fluid%20contamination%20due%20to%20poor%20quality
%20hoses,the%20use%20of%20low%20quality%20metals%20or%20materials.
https://gobdp.com/blog/hydraulic-fluid-leaks-how-to-diagnose-and-fix-them/
https://www.stratfordtyres.co.uk/resources/seized-brakes/

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