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Student Name: Wei-Hsiang Lin Student ID: 0003000193

Unit: AURLTTB101 – Inspect and service braking systems

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 Imagine Education
Student Assessment Cover
Sheet

Course Code AUR30620 Course Name Certificate III in Light Vehicle

Mechanical Technology
Unit Code AURTTB101 Unit Name Inspect and service braking systems

Due Date Assessment Name Automotive Portfolio

Part A: Short answer questions

Student No. ___0003000193____ Student Name _____Wei-Hsiang Lin_______

Student Phone ___0466069470__ Student Email

______Heineken.schweppes@gmail.com_________

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I declare that this assessment is my own work and where my work is supported by documents from
my workplace placement/employer permission has been granted.

Note: Filling out this coversheet as part of an electronic submission and approving the above information
will operate in the same way as physically signing this cover sheet.

Student name or signature: ___________________________________________

Office Use Only

Date/s Received: ___/___/___ ___/___/___ ___/___/___

Date/s Assessed: ___/___/___ ___/___/___ ___/___/___

Result of Assessment: ___________ ___________ ___________

Entered on Training Plan Moderation Signature

Note for Assessors: Filling out the above Office Use Only section as part of an electronic submission will
operate in the same way as physically signing this cover sheet. If not physically signed, Assessor must print
their name in signature box

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 Imagine Education
Assessment Questions
Part A

Course Code and Name: AUR30620 Certificate III in Light Vehicle Mechanical Technology
Unit Code: AURTTB101
Unit Title: Inspect and service braking systems

For this assessment you are required to answer all of the questions. You are permitted to research
the answers by reading the learner guide, text books, theory notes and accessing the internet. If
more room is needed label each task with the question number and use headings or dot points to
make your work clear for your trainer and assessor.

Please follow the Referencing Guide contained on your Course handbook.

Please attach a student assessment cover sheet to each unit submission. You must complete the
cover sheet in full detail.

1. Why is brake dust dangerous, and how can you ensure that it is controlled and safely
handled? Write your answer in 50-100 words.

Use proper PPE ,especially respirator and safety glasses. Be careful not to breathe the dust particles
left in a drum brake assembly when removing the brakes. The dust may contain asbestos, which can
seriously damage your lungs and cause illness.

Brake dust can be controlled by:

• Vacuum systems have unique plastic walls and fit tightly around a brake assembly or brake drum.
• Air gun used inside an enclosed box
• Exhaust used from brake drum to the box.

2. Why is brake fluid dangerous, and how should it be stored? Write your answer in 50-100
words.

Brake fluid is especially harmful to paintwork, so never try to mop up, scrub or wipe spills. Spills
should be washed away quickly with plenty of water.
Due to its affinity for moisture, do not use the fluid that has been stored for long periods after
opening. It is preferred to use fluid from a sealed previously unopened containe.

3. What are the environmental requirements and procedure for trapping, storing and disposing
of brake dust and brake fluid that has been released from a hydraulic braking system? Write
the information in the table below.
Environmental Trapping Storing Disposal
requirement and
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 procedure for:
Brake dust Use brake Put in save and special Recycle property.
cleaner/water with a place. Then tell to
tray under brake your manager.
system to collect.
Brake fluid Use brake Store an unopened Brake fluid is
cleaner/water with a container. especially harmful to
tray under brake Or collect waste fluid paintwork, so never
system to collect. to waste fluid bin. try to mop up, scrub
or wipe spills. Spills
should be washed
away quickly with
plenty of water.

4. Identify the following braking components and describe their functions. Write your answer in
20-40 words for each.

1. Brake rotor.
The rotors' primary purpose is to slow down the turning of the car's wheels by utilizing friction.
The brake rotor process occurs when calipers squeeze your car's brake pads together.

2. Brake pad.
A brake pad lies between the rotor and the caliper to reduce the level of friction from metal on
metal. Over time, the pads need replacing. When a driver applies the brakes, they may hear a
screeching sound, or the vehicle pulls to one sign. These are indications that the pads are worn.

3. Caliper.
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Calipers are found on each wheel and work to squeeze the brake pads against the rotors in an
effort to slow the spin of the wheel and get the vehicle to reduce its speed. When the brake pedal
is pressed, it forces hydraulic pressure on the pistons in the calipers to force the pads against the
rotors.

4. Brake drum.
Brake drums are an essential component of drum brakes. Together with the brake shoe, a brake
drum forms a friction pair, which decelerates the rotation of the wheel. The brake drum also has
the job of absorbing and discharging the heat generated during braking.
5. Brake shoes.
Brake shoes carry the brake lining inside brake drum systems. They are a curved piece of metal,
with a friction material fixed to one side. When the driver applies the brake, a wheel cylinder in
the drum brake system forces the brake shoe outward, against the inside of the drum.
6. Wheel cylinder.
A wheel cylinder is a component of a hydraulic drum brake. The wheel cylinder must force apart
the brake shoes and press them against the brake drum. This generates friction and the wheel is
decelerated.
7. Vacuum booster.
A brake booster, also known as a 'brake servo' or 'vacuum booster', does exactly as the name
suggests, it helps to 'boost' the performance of the brakes. A brake booster makes it easier for the
driver to brake by increasing the force exerted without the need for additional force applied on
the foot pedal.
8. Master cylinder.
The 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. Master brake cylinders are used both in disc brakes and drum
brakes.

5. How do the following braking systems work? Use 50-100 words for each system to write an
explanation.
a) Hydraulic braking system

The hydraulic braking system is a type of braking system in which, unlike the mechanical
braking system, hydraulic fluid is used to transmit the brake pedal or brake lever force from
the brake pedal or brake lever to the final drum shoes or disc caliper to achieve braking.

b) Mechanical braking system

Mechanical brakes are assemblies consisting of mechanical elements for the slowing or
stopping of shafts in equipment drives. They use levers or linkages to transmit force from
one point to another. Braking slows or stops the movement of the coupled shafts.

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 c) Air over hydraulic system

Air over hydraulic systems is a combination of parts of an air brake system and a hydraulic
brake system. It uses both air and hydraulic compression to operate the brakes.

d) Air braking system.

Air brake system is a type of friction brake for vehicles in which compressed air pressing on a
piston is used to apply the pressure to the brake pad needed to stop the vehicle.

6. How do you check the brake fluid in a car? Write your answer in 4 steps.

1. Shut the engine and open bonnet.

2. Locate brake fluid fill container.
3. Check level of brake fluid. It suppose between Max and Low.
4. Refill if lower than Low level.

7. How do you test the brake fluid in a vehicle?

Conductivity test: Conductivity test estimates the moisture content by converting the conductivity
into an estimated boiling point. Since brake fluids vary from formula to formula, this test is not an
accurate result unless the tester is calibrated to the manufacturer's product when new.

Boiling point test: boiling point tester is the only accurate way to test brake fluid performance

8. What is brake fluid’s chemical composition? Write your answer using 20 – 50 words.

DOT4 brake fluids are also glycol ether-based, but they contain borate esters in addition to
improve some properties, including increased dry and wet boiling points.

9. List the four (4) different types of brake fluid.

1. Dot 3
2. Dot 4
3. Dot 5
4. Dot 5.1

10. The problems listed in the table below cause uneven wear of the brake pads. Explain what
the effect is.
Problem Effect
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Rotor Thickness What has happened is the ceramic materials have transferred unevenly
Variation into the face of the rotor thus causing a thickness variation causing a pedal
pulsation
Sticky Caliper Pistons With a stuck or seized brake caliper, your car will have the tendency to pull
towards the side that has the sticky caliper. It will be similar to if you had a
bad alignment but usually more serious. This will happen not only when
braking but when you're simply driving.
Misalignment Cause your vehicle to shake when you are braking.

Dirty Rotors Disc brake rotors, or discs, normally wear out because they generate heat
to stop your car. Signs such as excess dust on the wheels, excessive
stopping distance, or strange noises and vibrations when braking can
indicate rotor warping, cracking, glazing or scoring. Consider replacing
them when these symptoms occur.
Different Types of It is important that you stay consistent with the type of brake pads that
Brake Pads you install in your braking system. Do not use different brands or materials
of brake pads because they are likely going to wear down at different rates
and have a completely different lifespan.

If you stay with the same model and thickness in your brake pads, then you
will have a better chance of them wearing evenly.

11. Why is brake bleeding required? Answer using 30 – 60 words

Bleeding the brakes is the process of pushing fluid through a hydraulic brake system to ensure all air
bubbles are removed. If brakes aren't bled and air bubbles are trapped within the brake fluid,
hydraulic pressure is greatly reduced, making the brakes less efficient.

12. How do you do bleed the brakes? List the six (6) steps.
13.
1. Locate the bleeder screw at the rear of the caliper body (or drum brake wheel cylinder.)
Remove the rubber cap from the bleeder screw.
2. Place the box-end wrench over the bleeder screw.
Place one end of the clear plastic hose over the nipple of the bleeder screw.
Place the other end of the hose into the disposable bottle.
Place the bottle for waste fluid on top of the caliper body or drum assembly. Hold the bottle with one
hand and grasp the wrench with the other hand.
3. Instruct the assistant to "apply." The assistant should pump the brake pedal three times, hold the
pedal down firmly, and respond with "applied." Instruct the assistant not to release the brakes until
told to do so.
4. Loosen the bleeder screw with a brief ¼ turn to release fluid into the waste line. The screw only
needs to be open for one second or less. (The brake pedal will "fall" to the floor as the bleeder screw
is opened. Instruct the assistant in advance not to release the brakes until instructed to do so.)

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5. Close the bleeder screw by tightening it gently. Note that one does not need to pull on the wrench
with ridiculous force. Usually just a quick tug will do.
6. Inspect the fluid within the waste line for air bubbles. Continue the bleeding process until air
bubbles are no longer present. Be sure to check the brake fluid level in the reservoir after bleeding
each wheel! Add fluid as necessary to keep the level at the MAX marking.

Notes: Begin at the corner furthest from the driver and proceed in order toward the driver. (Right
rear, left rear, right front, left front.) While the actual sequence is not critical to the bleed
performance it is easy to remember the sequence as the farthest to the closest. This will also allow
the system to be bled in such a way as to minimize the amount of potential cross-contamination
between the new and old fluid.

DO NOT release the brake pedal while the bleeder screw is open, as this will suck air back into the
system!

14. List six (6) steps to adjust the drum brake.

1. Hoist vehicle
2. Take tyres off
3. Locate the drum brake adjuster. You can easily access the brake adjuster at the rear base of the
brake drum. Remove the dust cover with a flat screwdriver.
4. Turn the brake adjuster clockwise or anti-clockwise to feel where you need to turn it to. It is
important to note that the most drum brake adjustment direction is clockwise. As you apply
your screwdriver downwards the brake adjuster moves upward to bring the brake shoes
closer to the drum.
5. Ensure that there is little drag to allow for an easy stoppage. If the drag is too much, the brake
won’t work properly. Once the tire can spin with a little drag (not freely or forcefully), you
need to do the same on the other wheel. Drag the hand brake lever to see how it is. If it’s too
free, add more adjustments.
6. Install all parts back and road test.

15. How do you adjust the manual parking brake in a vehicle? Write your answer in 50-100
words.

Release hand brake and hoist car. Take rear tyres off and locate a adjust hole from the brake rotor.
Try to find adjuster screw though the hole by rotating the brake rotor.
Attache a screw driver or an adjustment special tools to the hole then rotate the gear by flipping up
and down.
Test tightness by rotate the brake rotor. As long as feel the brake rotor can rotor but with resistance.

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 16. How does the EPB (Electric Parking Brake) system work? Write your answer in 50-100 words.

To actuate the system the driver simply pulls the park brake switch (or presses it down in some
cars). This sends a signal to the park brake control unit, which in turn sends a signal to activate
the electric motors on the rear brake callipers. These then apply the brake.

17. Identify the following tools and equipment.

Item Name
Respirator

Respirator removes contaminants from the

air, and is called an air-purifying respirator
(APR). APRs include particulate respirators,
which filter out airborne particles, and “gas
masks,” which filter out chemicals and
gasses.

Wheel Nuts

Support the brake rotors to install

Digital caliper: is a visual aid to take an

accurate measurement reading between
two graduation markings on a linear scale
by using mechanical interpolation, thereby
increasing resolution, and reducing
measurement uncertainty by using Vernier
acuity to reduce human estimation error.

Pressure gauge: An instrument for

measuring the condition of a fluid (liquid or
gas) that is specified by the force that the
fluid would exert, when at rest on a unit
area.

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 Return-spring tools

For removing and replacing return springs,

preventing damage and distortion.

Retaining-spring tools

For removing and replacing retainers and

springs. Their ends are shaped to fit against
the retainer and over the pin, making it
easier to compress the spring and turn the
retainer.

Brake lathe

Machining rotors actually takes of layers of

metal material and restores flat, smooth
surfaces to provide the proper friction
needed, minimizing noise-producing
vibrations and allowing for maximum pad
contact.

Safety stand: A robust, metal device that

can be securely locked at different heights
and helps support an already
elevated/raised portion of a vehicle.

Brake Service System

Exchanges oxidized brake fluid with new

brake fluid quickly and efficiently

18. Explain how the following post-service tests are conducted on braking systems.
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 a) static brake test, list 5 steps.

1. Release handbrake. Hoist vehicle as tyres leave from the ground.

2. Pump the footbrake pedal a few times until it becomes firm.
3. Footbrake pedal becomes firmer (this removes the vacuum in the brake servo unit)
4. The pedal will become progressively harder to press.
5. Shift D and pump footbrake pedal if brake work.

b) dynamic brake test, list 6 steps.

1. Ensure all wheel bolts in correct torque

2. Check tyres pressure
3. Road test
4. Emergence braking test. Stop speed maximum 110km/h to 0km/h without losing the direction
or spinning in different road and weather conditions.
5. Lane change test. Changing lanes in different road and weather conditions, without losing the
control of the vehicle when performing this manoeuvre.
6. Maintain speed to 60km/h and stop couples of time to ensure brake still works as every time

19. Where can you find the information you need to service and replace the brake components
in a vehicle, like the vehicle manufacturer specifications? Write your answer using 20 – 50
words

Check Job card to know and record which part should be repaired, replaced or serviced.
Check workshop procedure to find service and replace information. There are standard ways of
repairing. Search official website to ensure manufacturer specification which help you to get correct
components and not waste time to wait incorrect components.

20. Before you inspect and service brakes you will need to find the workplace procedures and
then select the tools and equipment required for the job. Write your answers using 100 –
150 words.
a) Where will you find the procedures?

You might ask supervisor or manager in workshop. To ensure what you need to do, you should check
Job card and service history. Or search information of procedures from qualified website.

b) How do you establish that the tools and equipment for the job are ready to be used?

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Always inspect first to ensure tools and equipment without visual damage or dirt.
Use tools or equipment in correct ways, include size, functions and max torque. Must follow
manufacturer specification. Tag fault tools or equipment and isolate them if necessary. Clean by rags
before put them back to the original place where you took.

c) What is the documentation procedure you complete?

Read owner’s manual and record what have you done on Job card and service history.
Use service and safety checklists to confirm completely without missing parts.
Follow recycle, safety and environment procedure while doing and done.

21. When a job has been completed there are some housekeeping procedures in the workshop
that you must complete. Explain how this is done in the table below.
Task Housekeeping procedure. Write your answers in 10 – 20 words

Tools and equipment Visual inspection before using. Clean them up before put them back.
Tag it if faulty. Isolate it if necessary.

Storage Tools should be stored in specific box to find them easily. Oil, fluid
and components should be stored in a shaded place away from
direct sunlight.
Faulty equipment Tag a faulty tag to remain people which fail to use. Isolate them
especially keep water away from electrical equipment or chemical
materials.

Excess material Store them properly follow manufacturer specification without

pollution and direct sunlight.

Recycling Follow recycle procedure. Put recycle materials in recycle bin. Do Not
put in waste bin. Waste oil or fluid put it waste oil bin.

Store properly and let authorized person to dispose.

22. The braking component in the picture below is from a diesel engine. Explain what it is and
how it functions.

The vacuum booster is a metal canister that contains a clever valve and a diaphragm. A rod going
through the center of the canister connects to the master cylinder's piston on one side and to the
pedal linkage on the other.

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The check valve is a one-way valve that only allows air to be sucked out of the vacuum booster. If the
engine is turned off, or if a leak forms in a vacuum hose, the check valve makes sure that air does not
enter the vacuum booster.

The vacuum booster is a very simple, elegant design. The device needs a vacuum source to operate.
In gasoline-powered cars, the engine provides a vacuum suitable for the boosters. In fact, if you hook
a hose to a certain part of an engine, you can suck some of the air out of the container, producing a
partial vacuum. Because diesel engines don't produce a vacuum, diesel-powered vehicles must use a
separate vacuum pump.

On cars with a vacuum booster, the brake pedal pushes a rod that passes through the booster into
the master cylinder, actuating the master-cylinder piston. The engine creates a partial vacuum inside
the vacuum booster on both sides of the diaphragm. When you hit the brake pedal, the rod cracks
open a valve, allowing air to enter the booster on one side of the diaphragm while sealing off the
vacuum. This increases pressure on that side of the diaphragm so that it helps to push the rod, which
in turn pushes the piston in the master cylinder.

As the brake pedal is released, the valve seals off the outside air supply while reopening the vacuum
valve. This restores vacuum to both sides of the diaphragm, allowing everything to return to its
original position.

23. Identify the different types of brake discs and brake pads in the table below.
Brake Components Type

Drilled and grooved

Drilled & Slotted rotors

Drilled and slotted rotors combine both of the

design aspects, advantages, and disadvantages
from their individual kin, as detailed above

These brake rotors are generally the most

expensive and are usually used in performance
applications or for aesthetics.

Dimpled and grooved

Increased dissipation of water, dust and road

grime from the contact area of your braking
system. Machined finish on the brake surface,
enhances initial brake performance. Longer life
in the metal composition and structure due to

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 heat tempering.

Drilled rotors

Drilled rotors literally have holes drilled in the

friction surface of the disc. The holes drilled into
the rotors surface assist with heat dispersion.
As a result, drilled rotors allow more air flow
through the disc are more effective, than
standard type rotors at controlling heat soak.

However, drilled rotors can wear unevenly and

develop cracks, especially when used in racing
and high-performance vehicles. This is because
the drilling of the material compromises the
integrity of the rotor casting. Drilled rotors must
have raw castings specially engineered for the
process.

Grooved

Slotted rotors

Slotted rotors have narrow slots machined

across the friction face of the disc. Slotted
rotors work very well in applications requiring a
heavy-duty alternative or competition vehicles.

This style of brake rotor delivers much

improved braking efficiency, by reducing the
build-up of gases (created by extreme heat in
the brake friction material) and other foreign
deposits on the friction surface of the disc that
get between the brake pad and the rotor. The
increase in braking efficiency gained by
installing slotted rotors means that not only is
the performance of the brake system greatly
improved, but the brakes will last longer as
well.

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 Semimetallic

Semi-metallic brake pads are very durable, as

well as heat-resistant and resistant to wear.
However, because these pads have a lower
friction coefficient when it comes to lower
temperatures, they need a little more pedal
power when the brakes are cold.

Semi-metallic brake pads are usually made of

either sintered graphite, iron, or steel, and,
therefore, they are great when you need the
high-performance capability in your vehicle. In
fact, these types of brake pads are perfect for
heavy vehicles and performance vehicles
because they are sturdy, well-made, and
diverse brake pads.

They contain up to 65% metal, but they also

are noisier to operate, wear down your rotors a
lot faster than other types of brake pads, and
don’t always perform well at low temperatures.

Cermet ceramic

A cermet is a composite material consisting of

ceramic (cer) and metallic (met) materials. The
ceramic in general has high temperature
resistance and hardness, and the metal has the
ability to undergo plastic deformation. A cermet
is ideally designed to have the combined
optimal properties of a ceramic and a metal.

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 Durable ceramic

The ceramic compounds used in these brake

pads help them to handle higher brake
temperatures, which makes them more reliable
in a wider range of temperatures and driving
conditions. These brake pads are highly durable
compared to the semi-metallic variety, and
produce less dust, resulting in cleaner wheels.

TOP Ceramic

The ceramic pads can handle a wide range of

temperatures and still deliver consistent
performance. Since they are more reliable in
varying weathers, ceramic pads provide a fast
recovery time after braking, produce less dust,
and handle high brake temperatures with less
heat fade.

Low metallic

Because of how these brake pads are made,

they tend to be quite noisy, and they spew out
a lot of brake dust. However, they have
excellent heat-transfer capabilities and are
made with up to 30% metal, such as copper or
steel. They are organic in nature and offer
excellent braking capabilities. Low-metallic
brake pads are great when it comes to braking
and heat transfer, and the materials that they
are made of are completely organic.

24. How do the calipers work in a disc brake? Write your answer using 20 – 50 words

The caliper is fed brake fluid through a banjo fitting which drives the piston forward towards the
inside brake pad when the brake pedal is pushed. This causes the caliper to move along the slide pins
which then pulls the outside brake pad up against the brake disc rotor.

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 25. What is the function of brake lining? Write your answer using 20 – 50 words

A brake lining is friction material attached to the face of a brake shoe, to cause frictional force when
the brake shoe makes contact with the brake drum.

26. What is the difference between a hydraulic brake booster and a vacuum brake booster?
Write your answer using 20 – 50 words

The hydro-boost power system works nearly identically to the vacuum-based system, but instead of
relying on vacuum pressure, it uses direct hydraulic pressure. It is powered by the power steering
pump and will typically fail at the same time as power steering.

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