Professional Documents
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LEARNING MATERIALS
Sector : AUTOMOTIVE
Welcome!
The unit of competency, "Service Brake System" is one of the
competencies of Automotive Servicing NC II; a course which comprises the
knowledge, skills and attitudes required for an Automotive Technician to
possess.
This unit of competency contains knowledge, skills and attitudes
required for Automotive Servicing NC II. This module contains training
materials and activities for you to complete.
You are required to go through a series of learning activities in order
to complete each learning outcome of the module. In each learning
outcome are Information Sheets, Self-Checks and Job Sheets. Follow these
activities on your own. If you have questions, don’t hesitate to ask your
instructor for assistance.
You may already have some or most of the knowledge and skills
covered in this learner's guide because you have been working for some
time already completed training in this area.
If you can demonstrate to your trainer that you are competent in a
particular skill or skills, talk to him/her about having them formally
recognized so you don't have to do the same training again. If you have a
qualification or Certificate of Competency from previous trainings, show it
to your trainer. If the skills, you acquired are still current and relevant to
the unit/s of competency they may become part of the evidence you can
present for RPL. If you are not sure about the currency of your skills,
discuss this with your trainer.
This module was prepared to help you achieve the required
competency in “Service Brake System”.
This will be the source of information for you to acquire knowledge
and skills in this particular competency independently and at your own
pace, with minimum supervision or help from your instructors.
Most probably your trainer will also be your supervisor or manager.
He/she is there to support you and show you the correct way to do things.
Your trainer will tell you about the important things you need to
consider when you are completing activities and it is important that you
listen and take notes.
You will be given plenty of opportunity to ask questions and practice
on the job. Make sure you practice your new skills during regular work
shifts. This way you will improve both your speed and memory and also
your confidence.
REMEMBER TO:
Work through all the information and complete the activities in each
section.
Talk to your trainer and agree on how you will both organize the
Training of this unit. Read through the module carefully. It is divided
into sections, which cover all the skills, and knowledge you need to
successfully complete this module.
Read information sheets and complete the self-check. Suggested
references are included to supplement the materials provided in this
module.
Use the Self –Check and Job Sheets at the end of each section to
test your own progress.
Talk to more experience workmates and ask for their guidance.
When you feel confident that you have had sufficient practice, ask
your instructor to evaluate you. The results of your assessment will be
recorded in your Progress chart and Accomplishment Chart.
PRE REQUISITE:
AUTOMOTIVE SERVICING NC II
LIST OF COMPETENCIES
Service Automotive
1. Servicing Automotive Battery ALT723303
Battery
Service Suspension
11. Servicing Suspension System ALT723315
System
CONTENTS:
Operating principles of brake system
Brake system types and components
Hydraulic brake system fluid
Changing hydraulic fluid
Personal safety procedures
Service procedures
CONDITIONS:
Students/trainees must be provided with the following:
Well ventilated workshop
Vehicle
Air compressor/air gun
Wheel wedge
Set of automotive hand tools
Hand gloves
Apron
Brake fluid
Rags
Service manual
Reference book
CDs
METHODOLOGIES:
Interactive discussion
Demonstration
Self-paced instruction
Video presentation
ASSESSMENT METHODS:
Interview
Written examination
Practical demonstration
Direct observation
CONTENTS:
Procedure in dismantling brake system component
Assembling brake components in accordance with standard
Applying personal safety in disassembling hydraulic parts
Using accurate tools for the job.
CONDITIONS:
Students/trainees must be provided with the following:
Vehicle
Well ventilated workshop
Washing pan
Air compressor/air gun
Hydraulic jack
Tire wrench
Set of automotive hand tools
Hand gloves
Apron
Brake fluid
Clean rags
Service manual
Reference books
CDs
METHODOLOGIES:
Interactive discussion
Demonstration
Self-paced instruction
ASSESSMENT METHODS:
Interview
Written examination
Practical demonstration
Direct observation
LO3. CONDUCT ROAD TEST
ASSESSMENT CRITERIA:
1. Pre-starting check-up is performed prior vehicle operation.
2. Vehicle driven at specified speed to detect brake trouble.
3. Findings are recorded and recommendation is given.
CONTENTS:
Pre starting check-up
Brake troubles
Driving techniques
Vehicle safety requirements.
Adjusting/setting emergency/parking brakes
CONDITIONS:
METHODOLOGIES:
Interactive discussion
Demonstration
Self-paced instruction
ASSESSMENT METHODS:
Interview
Written examination
Practical demonstration
Direct observation
LEARNING OUTCOME SUMMARY
ASSESSMENT CRITERIA:
CONTENTS:
CONDITIONS:
METHODOLOGIES:
Interactive discussion
Demonstration
Self-paced instruction
ASSESSMENT METHODS:
Interview
Written examination
Practical demonstration
Direct observation
LEARNING EXPERIENCES
Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
Base brake components are the parts of the brake system found on
all vehicles (Figure 10.1-1.1). The term “base brakes” does not
include antilock brakes or traction control systems
Brakes slow and stop a vehicle when the brake linings contact the
drums or rotors using friction to convert kinetic energy to heat
energy. The intensity of the heat is proportional to the vehicle speed
and the degree of deceleration. Faster speeds and quicker stops
equal more heat.
Today's high performance hydraulic brake systems have been
developed over many years, through a constant evolution of design
and component improvements.
Disc Brake Type: The major components of disc brake are the
rotor, caliper and brake pads (Fig 10.1-1.3).
Drum brakes
There are two main types of drum brakes, Duo servo and leading
trailing. In the duo servo application, the primary brake shoe transfer
force to the secondary brake shoe during braking. The secondary
brake shoe is longer and thicker than the primary brake shoe
because the secondary shoe contributes more braking power. In
leading-trailing applications, the leading brake shoe provides most
of the braking power. The trailing shoe contributes braking power
only when the wheels slows down.
5. Primary brake shoe – is the first shoe to come in contact with the
drum during forward braking. As it contacts the drum it is forced in
contact with the adjusting screw which multiplies and transfers
energy to the secondary shoe. The lining is usually shorter than the
secondary shoe lining.
7. Return springs – holds the brake shoes away from the brake
drum until the brakes are applied.
8. Hold down pin and spring – it keeps the brake shoes aligned with
the backing plate.
Figure 10.1-1.11: Duo- servo drum brake
Figure 10.1-1.12b:
Brake released
REFERENCES/FURTHER READING
Crouse, William H. and Anglin, Donald L.; Automotive Mechanic; 10th
ed.; McGraw Hill International Edition, 2004.
GM service technical training book (CD, SWG)
Self-Check 10.1-1
Multiple choice: Write the letter of the best answer on the blank space
provided before each number.
a) Brake pad
b) Caliper
c) Brake shoe
d) Rotor
COLUMN A COLUMN B
___1. Connecting spring A) pushes the brake shoe by
converting hydraulic pressure
into mechanical force.
MULTIPLE CHOICE:
1. d
2. b
3. b
4. b
5. d
MATCHING TYPE
1. E
2. A
3. G
4. B
5. C
6. F
7. D
IDENTIFICATION
Information Sheet 10.1-2
Brake Hydraulic System Brake Fluid
Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
Brake Fluid
The exact amount of water allowed in the brake fluid and how the
boiling point is determined are covered in standards issued by
Society of Automotive Engineers (SAE) and Federal Motor Vehicle
Safety Standards (FMVSS). The fluids are normally referred to by
their Department of Transportation (DOT) numbers. The primary
types of brake fluid are DOT3, DOT4, DOT5 and DOT5.1.
WARNING
You should never mix silicone and polyglycol brake fluids. DOT 5 will
not mix with DOT 3, DOT 4 and DOT 5.1 brake fluids. It will float on
top, compromising brake efficiency and possibly causing injuries.
Additionally using DOT 5 in systems designed for DOT 3, DOT 4 or
DOT 5.1 can cause the rubber seals to swell resulting in improper
brake operation. Mixing DOT 3 and DOT 4 together will lower the
boiling point of the mixture, reducing brake pressure and creating a
safety hazard. Its best to use the brake fluid specified by the vehicle
manufacturer. If you need to replace a contaminated fluid be sure to
thoroughly flush the system before changing it.
REFERENCES/FURTHER READING
Crouse, William H. and Anglin, Donald L.; Automotive Mechanic;
10th ed.; McGraw Hill International Edition, 2004.
GM service technical training book (CD, SWG)
Multiple choice: Write the letter of the best answer on the blank
space provided before each number.
___1. Which of the following brake fluid has the lowest boiling
point?
a. DOT 3 c. DOT 5
b. DOT 4 d. DOT 5.1
___ Fluid flows to the front and rear brakes regulated by metering,
proportioning or combination valve.
___ Fluid causes the brake calipers and wheel cylinders to apply
and the vehicle stops.
Answer key 10.1-2
Multiple choice.
1. a
2. c
3. b
4. b
5. b
1. T
2. T
3. F
4. F
5. T
Chronological sequencing.
1. 3
2. 4
3. 1
4. 2
5. 5
Information Sheet 10.1-3
SAFETY INSTRUCTIONS IN OPERATING 2 POST LIFTS
Steps/Procedure:
1. Gather instruction and relevant materials
2. Read and follow manufacturer’s manual safety precautions
3. Identify the parts of the 2 post lift
4. Lift the vehicle, follow the steps listed below:
A. Before Loading: Lift must be fully lowered and service bay clear of all
personnel before the vehicle is brought on lift. Swing arms out to full drive-
thru position.
B. Spot vehicle over lift. Make sure you are using the correct adapter,
Fig. 10.1-1.1
C. Loading: Swing arms under vehicle and position adapters at vehicle
manufacturer’s recommended lift points, Fig. 10.1-1.2. Use intermediate,
high step, or optional adapters for under body clearance when required.
D. To Raise Lift:
a. Push Raise switch on power unit, Fig. 10.1-1.3.
b. Stop before making contact with vehicle. Check arm restraint pins for
engagement. If required, slightly move arm to allow restraint gear and
pawl to mesh. DO NOT hammer pin down as this will damage the
restraint gear teeth.
c. Raise vehicle until tires clear the floor.
d. Stop and check adapters for secure contact at vehicle manufacturer’s
recommended lift points.
e. Continue to raise to desired height only if vehicle is secure on lift.
f. Do Not go under vehicle if all four adapters are not in secure contact at
vehicle manufacturer’s recommended lift points.
g. Repeat complete spotting, loading and raising procedures if required.
h. Lower lift onto locking latches.
Adapter Recommendations
Fig, 10.1-1.1
Assessment Method:
Practical Demonstration
Direct Observation
Performance Criteria Checklist 10.1 - 1
CRITERIA
YES NO
Did I….
1. Gathered instruction and relevant materials?
Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
Figure 10.1-4.4
Figure 10.1-4.5
2. BRAKE LINES/HOSES
- Check the lines and
hoses for leaks, cracks,
splits and swelling.
Figure 10.1-4.6
REFERENCES/FURTHER READING
Crouse, William H. and Anglin, Donald L.; Automotive Mechanic;
10th ed.; McGraw Hill International Edition, 2004.
GM service technical training book (CD, SWG)
SELF CHECK 10.1-4
Chronological Sequencing Test:
Arrange in correct sequence in preparing a vehicle for
inspection. Write the sequence number before each statement.
____ Remove the lug nuts and the wheel and tire assembly.
____ Check the brake fluid. If the brake fluid is above the ADD
mark and you know that the pads will be replaced drain the fluid to
the ADD mark by opening the caliper bleeder screws.
Enumeration:
Enumerate what to check in the following brake components
1. Caliper assembly
a)
__________________________________________________________________
____
b)
__________________________________________________________________
____
2. Brake lines/hoses
a)
__________________________________________________________________
____
b)
__________________________________________________________________
____
c)
__________________________________________________________________
____
d)
__________________________________________________________________
____
3. Rotor
a)
__________________________________________________________________
____
b)
__________________________________________________________________
____
Answer key to SELF CHECK 10.1-4
Chronological sequence
3
2
1
Enumeration
1. a) check for any damage
b) caliper should move smoothly
Assessment Method:
Demonstration & Direct observation
Performance Criteria Checklist 10.1 - 1
CRITERIA
YES NO
Did I….
1. Identified and prepared all the equipment and
materials to be used?
2. Moved and position vehicle in the middle of the lift?
3. Selected the appropriate adapter for the vehicle?
REFERENCES/FURTHER READING
Crouse, William H. and Anglin, Donald L.;
Automotive Mechanic; 10th ed.; McGraw
Hill International Edition, 2004.
GM service technical training book (CD, SWG)
Self- check 10.1-5
Chronological Sequencing Test:
Arrange in correct sequence in disassembling disc brake
components. Write the sequence number before each statement.
1
3
2
4
JOB SHEET 10.1-2
CRITERIA
Did I…. YES NO
Safety Shoes
2 post hoist/lift
Training vehicle
Air compressor
Rags
Service manual
Tagged components
Tagged components