AUTOMOTIVE
`HANDBOOK
`
`2nd EDITION
`
`TOYOTA Ex. 1116, page 1
`Toyota v. Hagenbuch
`|PR2013-00638
`
`TOYOTA Ex. 1116, page 1
`Toyota v. Hagenbuch
`IPR2013-00638
`
`

`

`
`
`Ished by:
`.
`
`gmfikoben Bosch GmbH, 1986
`0—7000 Stuttgart 1.
`
`mflaChvso’Equipment Product Group,
`for Technical Information
`
`
`
`
`7 Editors:
`Dipl‘.—lng (FH) H. Bauer,
`
`'
`'l.—in W. Bazlen,
`ifittilinklger Marlon Herwerth
`
`Production management:
`
`
`
`
`
`‘ Translation:
`Editor-in-Chief:
`
`'P. Glrling
`Editor:
`
`. F. Salas
`.
`Translated by:
`
`lngenieurbiiro fitr Techntsche und
`
`Naturwissenschaftliche Ubersetzungen
`Dr. W.-D. Haehl GmbH, Stuttgart,
`Edward L. Crosby Ill
`
`Technical graphics:
`
`
`Bauer & Partner GmbH, Stuttgart
`Joint production:
`
`Jaeger Druck GmbH, Speyer
`The worldwide selling rights and the
`
`right to issue foreign—language licenses
`
`for
`the original German Edition (19th
`Edition, 1985) are held by:
`
`VDl-Verlag, GmbH
`Verlag des Vereins Deutscher
`lngenieure, Graf—Flecke—Str. 85,
`D-4000 DiJsseldorf 1,
`ISBN 3-187418006—9
`
`Reproduction, duplication and transla-
`
`tion
`of
`this
`publication,
`including
`excerpts therefrom,
`is only to ensue
`with our previous written consent and
`with particulars of source. Illustrations,
`descriptions, schematic'diagrams and
`other data serve only for explanatory
`purposes and for presentation of the
`text. They cannot be used as the basis
`for design,
`installation and scopeof
`delivery. We undertake no liability for
`conformity of the contents with national
`or local regulations.
`We reserve the right to make changes.
`The brand names given in the contents
`serve only as examples and do not
`represent the classification or prefer-
`ence for a particular manufacturer.
`Trade marks are not identified as such.
`
`The following companies provided illus—
`trations and informative material:
`
`-
`Audi AG, Ingolstadt;
`Bayerische Motorenwerke AG, Munich;
`Daimler-Benz AG, Stuttgart;
`J. Eberspacher, Esslingen;
`Fichtel u. Sachs AG, Schweinfurt;
`Kienzle Apparatus GmbH, VS~Villingen;
`Sekurit-Glas Union GmbH, Aachen;
`Voith GmbH, Heidenheim;
`.
`Zahnradfabrik Friedrichshafen AG, .
`Friedrichshafen.
`Printed in the
`Federal Republic of Germany,
`Imprimé en République Fédérale
`d’Allemagne.
`Editorial closing: 30.9.1986
`
`
`
`
`
`
`Approved Editions under license:
`SAE Society of
`Automotive Engineers Inc.
`lSBN 0789 283-518—6
`Delta Press Limited
`lSBN 1 85 226 00 9
`
`
`
`
`
`TOYOTA Ex. 1116, page 2
`Toyota v. Hagenbuch
`lPR2013-00638
`
`TOYOTA Ex. 1116, page 2
`Toyota v. Hagenbuch
`IPR2013-00638
`
`

`

`Fuel Metering (Spark Ignition Engines)
`362
`
`Diagram of a governor carburetor.
`1 /d/e curroff valve, 2Acce/ensror pump, 3 [die
`system, 4 Compound choke valve, 5 Booster,
`6 Main metering systems. 7 Fol/405d enrichment sysrem, 8 Float, 9 Fuel supply, 10 Float need/s ‘
`valve, 11 idle mixture adjustment screw, 12 Throttle I/a/ves, 13 Venturi' 14 Pen—load enrichment
`valve
`
`
`
`
`
`
`
`11 tst Stage 13 12
`
`14 2nd Stage12 13
`
`
`
`
`the throttle valve gap.
`
`Carburetors lor 6-cylinder Engines
`The doublesbarrel carburetor consists of
`two carburetors of equal size connected
`in parallel which share a common float
`chambers Both throttle valves open
`simultaneously. The double-barrel com—
`pound carburetor has
`four mixing
`chambers: and lsadvantageous in terms
`of operation in the parteload range.
`Special Carburetors
`Special carburetors are available for off-
`road
`vehicles. These
`have
`float
`chambers designed such that an Optie
`mum airvfuel mixture is delivered, even if
`the vehicle is at an extreme tilt.
`
`Carburetor Design and
`Principle of Operation
`The driver actuates the throttle valve by
`means of the accelerator. The throttle
`valve controls the amount of air aspirated
`by the engine. The carburetor then
`meters an appropriate amount of fuel
`depending upon this quantity of air.
`
`Engine power is thus determined by the
`position of the throttle Valve.
`The float. in conjunction with the float
`needle valve, regulates the fuel flow to
`the carburetor. and holds the fuel level in
`the float chamber constant. The closing
`force of the float needle is augmented by
`the lever action of the linkage.
`The amount of air aspirated by the
`engine is measured in the carburetor by
`means of a venturi. The reduction in
`cross section in the venturi increases air
`velocity. thus creating a corresponding
`vacuum at the point of least cross sec-
`tion. This pressure differential between
`the venturi and the float chamber, which
`can be further increased by a booster. is
`used to drawfuelfrom the float chamber.
`In the tixed-venturi carburetor, the main
`metering system and several auxiliary
`systems match the amount of fuel to the
`amount of aspirated air. Very good air-
`fuel mixture formation is provided by the
`high air-stream velocity in the venturi and
`
`TOYOTA Ex. 1116, page 3
`Toyota v
`. Hagenbuch
`|PR2013
`-00638
`
`TOYOTA Ex. 1116, page 3
`Toyota v. Hagenbuch
`IPR2013-00638
`
`

`

`Braking Equipment (Passenger Cars)
`526
`
`Vacuum booster
`The vacuum booster is a pedal-force
`booster which is combined with a tan—
`dem master cylinder. The boost factor 1‘
`(see characteristics) can be varied in
`design by an appropriate choice of
`lever control. Via the lever control. a
`proportional assisting force is superim-
`posed on the pedal force, and both act
`together on the tandem master cylin—
`der. At the same time, a reactive force
`is
`conveyed
`to
`the
`driver, which
`enables
`him to meter
`the braking
`action correctly. The operating prin—
`ciple is explained in the diagram below.
`Should the booster fail, there remains
`only the pedal force.
`
`to the pedal
`
`pressure is proportional
`force.
`.
`I, which
`The port for brake circuit
`supplies the rear drum brakes, has a
`prepressure valve which assures
`a
`residual pressure of approx. 1.5 bar
`when the brakes are released, This pre-
`vents
`the entry of air
`through the
`wheel-cylinder seals. The brake circuits
`for disk brakes do not have any pre-
`pressure. With the brakes released, the
`two snifter holes guarantee that there
`can
`be
`temperature-
`and
`leakage
`related changes in quantity and press-
`ure between the fluid reservoir and the
`brake circuits.
`
`
`Operating principle in case of failure of
`a brake circuit:
`Tandem master cylinder
`— Failure of brake circuit I
`The tandem master cylinder is operated
`either directly via a pedal ratio or, if the
`The push-rod piston moves forward as
`pedal force is not sufficient, via a pedal—
`far as
`the intermediate piston and
`force booster (e.g. vacuum booster).
`mechanically transmits the force to the
`intact brake circuit
`ll, which can thus
`Operating principle: after passing over
`snifter hole I, the push—rod piston for-
`produce the full brake pressure.
`ces the brake fluid into brake circuit |.
`— Failure of brake circuit ||
`The compression of the spring and the
`The intact brake circuit
`l hydraulically
`pressure buildup in brake circuit | actu—
`pushes the intermediate piston against
`ates the intermediate piston, which
`the stop in the housing. It is then poss—
`passes over snifter hole ll and builds up
`ible for the full brake pressure to be
`produced in brake circuit l.
`pressure in brake circuit II. The brake
`
`Vacuum brake booster with lever control
`Characteristics of vacuum brake booster
`as a function of active diameter.
`1 Output force {to tandem master cylinder),
`2 Vacuum connection, 3 Input force (pedal
`{type = active diameter in inches) at
`force), 4 Atmosphere, 5 Working pressure.
`vacuum {0.8 bar)
`
`3000 N
`2000
`1000
`Input force FE
`= Pedal force x pedal ratio
`
`FA
`Boost factor: = tan a :
`FE - Fa
`
`F0
`
`
`
`
`
`llll/I’”’”/Ill/li’7/
`
`
`
`
`
`
`forceFu
`Assisting
`
`
`
`OutputforceFA
`
`
`
`
`
`
`
`TOYOTA Ex. 1116, page 4
`Toyota v. Hagenbuch
`|PR2013-00638
`
`TOYOTA Ex. 1116, page 4
`Toyota v. Hagenbuch
`IPR2013-00638
`
`

`

`527
`Braking Equipment (Passenger Cars)
`
`
`Tandem master cylinder.
`1 Two-chamber fluid reservoir, 2 Housing,
`3 Shifter hole for brake circuit ll,
`4 Compression spring, 5 Snifter hole for
`brake circuit I, 6 Push—rod piston, 7 Front
`brake circuit ll, 8 intermediate piston,
`.
`»
`,
`9 Pre-pressure valve, 10 Rear bra/(e circuit l
`
`The failure of a brake circuit causes a
`considerable reduction in the braking
`effect, a clearly noticeable increase in
`the pedal travel and the loss of brake
`fluid from one of the two chambers of
`the fluid reservoir.
`
`ressure re ulatin valve
`Brake
`The more heavily the driver brakes, the
`greater
`is
`the dynamic shifting of
`weight from the rear axle to the front
`axle. With the vehicle empty, the brak-
`ing force at the rear axle may be so
`great that the rear axle locks before the
`front axle. This can lead to instability
`when braking,
`i.e. to skidding. Braking
`stability is obtained when, irrespective
`of vehicle loading, the front axle always
`looks before the rear axle (see charac-
`teristics opposite and legal
`require-
`ments p. 508). The correct braking—
`force distribution can be achieved by
`brake-pressure—regulaiing valves which
`are installed in the brake lines to the
`wheels of the rear axle. Matched to the
`respective vehicle data, there are vari-
`ous kinds of brake-pressure-regulating
`valves:
`- Brake—pressure—regulating valve with
`fixed changeover pressure,
`~ Load-sensitive brake-pressure—regu-
`lating valve with variable changeover
`pressure dependent on vehicle loading.
`The load-sensitive brake-pressure—
`re ulatin
`valve
`is mounted in
`the
`region of the rear axle. The compres—
`sion of the suspension between axle
`and body is used as a measure of the
`vehicle loading and is transmitted via a
`mechanical
`linkage
`to the
`control
`spring in the brake-pressure-regulating
`valve. The control spring acts on a
`stepped piston. During initial braking,
`the control spring keeps the valve seat
`at
`the stepped piston open until
`the
`brake pressure has reached a
`level
`which, according to the active area of
`the stepped piston, corresponds to the
`force of the control spring. The further
`increase
`in
`pressure
`beyond
`the
`changeover point takes place along a
`slope corresponding to the difference
`in the active diameter of the stepped
`piston.
`
`
`
`
`Characteristics of a load-sensitive brake-
`pressure-regulating valve.
`2 bar
`
`
`a
`Unregulated w
`t.
`/
`% 8°
`I???
`5':
`sol—
`4%???
`x
`1‘
`/
`/////
`E
`
`
`;
`figéf/
`
`
`k 20
`'1 Unladen
`
`o ‘
`i
`l
`é
`0
`40
`80
`120 bar
`Front-axle brake pressure
`
`
`
`
`
`
`
`Load-sensitive brake pressure regulating
`valve.
`1 From tandem master cylinder,
`2 To wheel brakes, 3 Mechanical linkage,
`4 Control springs, 5 Stepped piston.
`
`Unladen
`
`
`
`
`
`
`
`
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`TOYOTA EX. 1116, page 5
`Toyota v. Hagenbuch
`|PR2013-00638
`
`TOYOTA Ex. 1116, page 5
`Toyota v. Hagenbuch
`IPR2013-00638
`
`