Bosch Braking Systems www.boschautoparts.in Engineered to ensure reliable stops Innovation in the Best Tradition When it comes to automotive technology, Bosch has always led from the front, pioneering innovations that have enabled a safer and a more comfortable on-road experience across the world. Especially in the brakes department, Bosch is the pacesetter for modern safety technology. From the first vacuum-assisted brakes in 1927, through Anti-lock Braking Systems (ABS), right up to the electronic driving systems of the latest generation, Bosch provides the deciding influence, from prototype to series production. Contents Introduction 4 Bosch Braking System Advantage 5 Foundation Mechanism 7 Transmission Mechanism 9 Actuation Mechanism 10 Foundation Mechanism: Applications 13 Brake Pad Kits 14 Brake Shoe Kits 16 Brake Liner Kits 17 Wheel Cylinder Kits 17 Wheel Cylinder Assemblies 18 Brake Discs 20 Transmission Mechanism: Applications 23 Brake Fluids 24 Actuation Mechanism: Applications 25 Passenger Cars 26 Non-OE Actuation Parts 35 Non-PC Actuation Parts 35 GST Details 38 3 Uncompromising Quality Safety Knows no Compromise The braking system is crucial to the safety of the vehicle occupants. Uncompromising quality is demanded so that the vehicle driver can depend on uncompromised functionality, 100% of the time, as well as the highest braking comfort characterised by: Tested under Excellent response behaviour Precise operational sensitivity Extreme Without noise and vibration Consistent action Conditions Designed for extreme loads Bosch is always testing its braking system components under severe The loads that a braking system must handle are enormous. These conditions in the development phase. systems are subjected to environmental influences such as moisture, Prototypes are then installed in the salt, dust, and dirt. Above all, brakes are subjected to extreme forces vehicle that they are intended for much greater than the forces from an engine. and tested in every imaginable road condition and climatic condition. Complete Programme in Original Equipment Quality The high-quality measures from original equipment apply in the aftermarket sector too. Bosch offers a broad range of products for distributors and workshops in the: Foundation Mechanism Transfer Mechanism Actuation Mechanism Bosch supports workshops with brake service tools and testing technology for every possible requirement. In addition, the Bosch training package is just as high-quality as the product itself, for effective and safe brake installation and repairs. Professional and practice-oriented service trainings provide the workshops with information on the latest technological developments in the automotive world. Bosch’s technical hotline provides further assistance in case of unexpected problems. 4 Bosch Braking System Advantage With high-quality auto parts, state-of-the-art diagnostic equipment, and world-class service, we keep vehicles moving. Here are ten reasons why distributors and workshops prefer Bosch: Trust: Being one of the Precision: world’s leading Individually automotive designed Certified quality: systems and tested Vehicle manufacturers, solutions for manufacturers Bosch ensures every vehicle have come to rely that every make. on Bosch’s high product meets quality standards the stringent Consistency: and testing quality demands High quality procedures, of original products especially in the equipment tested in the aftermarket. manufacturers. toughest Wide coverage: conditions Bosch products ensure are designed for reliability and a wide range of long-lasting vehicle models. performance. Sales promotion: Comprehensive advertising, extensive technical information, and communication aids. Training: Superior Seminars diagnostics: and training Bosch provides Standard programmes Technical powerful performance: are conducted support: diagnostics Bosch brake at modern Workshops featuring modular components training centres can avail high- construction always exceed across India for end testing and up-to-date legal standards. professionals. technologies, ESI[tronic] Technical hotline, knowledge software. knowledge resources, and database, and services from a comprehensive single source. information sheets provide further support. 5 The Complete Braking System Programme Bosch is among the leading international manufacturers of braking systems. All the production occurs under stringent quality criteria in the company’s own facilities across the world. From developing individual components to complete systems, Bosch guarantees the highest degree of functionality by means of intensive research and close cooperation with vehicle manufacturers. Braking System Components The product programme in the aftermarket for brakes consists of the following: Foundation Mechanism: Presses the pads onto the brake disc or brake drum. Drum Brake Shoes Disc Brake Pads Wheel Cylinder Kits Brake Discs Wheel Cylinders Transmission Mechanism: Transfers the brake force via brake lines and brake hoses with brake fluid. Brake Fluids Actuation Mechanism: Triggers and controls braking effect. Foot pressure affects the brake booster through the brake pedal. The master cylinder converts the increased actuation force into hydraulic pressure. Master Cylinders Brake Boosters Brake Force Regulators Clutch Slave Cylinders Clutch Master Cylinders 6 Foundation Mechanism Brake Pads Features and Benefits: Advanced friction technology ensures excellent stopping distance Asbestos-free construction prevents exposure to harmful cancer-causing substances Optimum friction coefficiency for superior response Improved resistance to wear and tear for long operating life Designed as per OE specifications with better NVH characteristics Coated Pads – Pioneering Technology for Good Bedding-In Features and Benefits: Contact Optimiser Technology – Abrasive compound High-performance special brake pads manufactured on surface of friction material provides: using RMR shims which offer: Reduced braking distance due to enhanced initial Insulation against the vibrations caused during contact between the pad and the disc braking Immediate removal of contaminants and residues Heat insulation and dampness, further extending its due to the presence of the optimiser lifespan Increased contact area between the disc and the Quiet braking by obstructing the noise between the pad by polishing the disc to smoothen it backplate of the brake pad and the caliper Reduced occurrence of hot spots due to friction, leading to enhanced life and performance Bedding-In – Instructions and Benefits: Bedding-in is a process where the pad and disc alignment happens. It helps to transfer the even layer of brake pad material on the brake disc which assists in smoother braking operation and improved braking performance. Step 1: Fit the brake pads as per the recommended Caution: Do not apply excessive pedal pressure or procedure ensuring cleaning of all the sliding continuous braking. surfaces and greasing of caliper pins with Step 4: Repeat Step 3 at least 10–15 times. silicon-based grease suitable for operation at high temperatures. *PS: For the red-coated pads: The bedding-in between the coated pads and the surface of the existing brake disc Step 2: After the fitment and servicing are complete, may initially have a rubbing noise which indicates that ensure a trial run of 3–4 km to understand smooth the uneven surfaces on the disc are getting polished and performance of the vehicle after servicing. matched properly with the surface of the new pads. Step 3: Accelerate gradually to a speed of 50 kmph The rubbing noise of the abrasive material will disappear and apply the brakes. Slow down to 10 kmph along with the red coating, and braking will be smooth without stopping. This will help the bedding-in and efficient. process. 7 Brake Shoes Brake shoes carry the brake lining in the drum brakes used in automobiles, and belong to the most stressed parts of a braking system. They consist of a mount and a lining. The lining is fixed directly onto the mount. Extreme temperature difference can cause cracking of the shoes. Hence, they should be checked and replaced every few years as a safety precaution. Bosch brake shoes feature a host of high-performance properties, ensuring reliable response even in conditions of high stress. Features Advanced friction formulation 100% asbestos-free construction Optimal coefficient of friction Brake Discs Rust-inhibitive coating While braking, most pressure is applied on the brake Benefits disc. Made from high-quality cast steel, Bosch brake discs Extended wear, consistent performance, and long are resistant to corrosion and wear, providing assured service life stopping power over a long operating life. Designed for Elimination of exposure to harmful friction materials high performance in the most extreme conditions, Bosch brake discs are featured as original equipment by leading Assured quality and safety automakers in their vehicles. Protection against rust Cast in Steel Improved engine performance and higher vehicle weights are increasing the quality requirement for braking systems. Only brake discs made from high-grade materials and homogenous casting structures without trapped air and friction will meet the specifications of the car manufacturers. Minimal Tolerances for Disc Thickness Variation (DTV) and Run-out These characteristics are essential for best braking comfort. Considerable variation of the friction ring’s thickness generates immediate vibrations (oscillating