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OMPETEN Y BASED LEARNING
MATERIAL
Sector:
AUTOMOTIVE
Qualification:Automotive Servicing NC II
Unit of Competency:
Service Brake SystemModule Title:
SERVICING BRAKESTechnical Education and Skills Development
AuthorityEast Service Road, South Superhighway, Taguig, Metro Manila
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NATIONA CERTI!ICATE EVE "#UAI!ICATION EVE
COM$ETENC%&BASE' EARNING MATERIAS
No( Unit o) Com*etency Mo+u,e Tit,e Co+e
7. Service Starting System Repairing Starting System ALT72!7
". Service #harging System Repairing #harging System ALT72!"
$. Service Engine MechanicalSystem
Servicing #ooling System ALT72!$a
Servicing Lu%ricating System ALT72!$%
Servicing &asoline 'uel System ALT72!$c
Servicing Air (nduction System ALT72!$d
Servicing )iesel 'uel (n*ector ALT72!$d
+!. Service #lutch System Servicing and Repairing #lutchSystem
ALT72+!
++. Service )ierential and 'ront A-le Servicing )ierential and 'ront
A-le
ALT72++
+2. Service Steering System Servicing Steering System ALT72+2
+. verhaul Manual Transmission /ulling0out, )isassem%ling and#hec1ing Manual Transmission
ALT72+a
Assem%ling and Testing ManualTransmission
ALT72+%
-.( Service Brake System (dentiying and E-plainingydraulic 3ra1e Systemperations and 'unctions
ALT72+4a
Servicing Brakes AT/"00-.1
verhauling 3ra1e Systems ALT72+4c+5. Service Suspension System Servicing Suspension System ALT72+5a
(dentiying and E-plainingSuspension System perating/rinciples, #omponents and'unctions6#onventional and AirSuspension
Servicing and RepairingSuspension System
ALT72+5%
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About this Competency Based Learning Material
8elcome to the module 9Servicing Brakes2. This learning material contains trainingmaterials and activities or you to complete.
The unit o competency :Service Brake System: contains the 1nowledge, s1ills andattitudes re;uired or Automotive Servicing( (t is one o the specialiou are re;uired to go through a series o learning activities in order to completeeach learning outcomes o the module. (n each learning outcome there are InformationSheets and Resource Sheets 6Reerence Materials or urther reading to help you %etter understand the re;uired activities. 'ollow these activities on your own and answer the sel0chec1 at the end o each learning outcome. >ou may remove a %lan1 answer sheet at theend o each module 6or get one rom your acilitator?trainer to write your answers or eachsel0chec1. ( you have ;uestions, don@t hesitate to as1 your acilitator or assistance.
Recognition o) $rior earning 3R$4
>ou may already have some or most o the 1nowledge and s1ills covered in thislearning material %ecause you have
• %een wor1ing or some time
• already completed training in this area.
( you can demonstrate to your trainer that you are competent in a particular outcome,you donBt have to do the same training again.
Tal1 to your trainer a%out having them ormally recogni
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DCAL('(#AT(= AUTOMOTIVE SERVICING NC II
C=(T ' #M/ETE=#> Service Brake System
M)CLE Servicing Brakes
(=TR)C#T(=
The modern automotive %ra1e system has %een reined or over +!! years and has %ecomee-tremely dependa%le and eicient.
A %ra1e is a device or slowing or stopping motion, as o a vehicle, especially %y contactriction.
The typical %ra1e system consists o dis1 %ra1es in ront and either +isk or +rum 1rakes inthe rear connected %y a system o tu%es and hoses that lin1 the %ra1e at each wheel to themaster cylinder. ther systems that are connected with the %ra1e system include the par1ing%ra1es6 power %ra1e %ooster and the anti&,ock system.
This module will guide you in learning the %asics o %ra1e systems and provide useul tips inperorming %ra1e system preventive maintenance. As you progress in this module you will learnhow to diagnose %ra1e system ailure and perorm tests on anti0loc1 %ra1e system components. LEAR=(=& CT#MES
At the end o this module you will %e a%le to
L +. /erorm %ra1e system preventive maintenance.
L 2. )iagnose %ra1e system ailure.
L . /erorm A3S component testing.
ASSESSME=T #R(TER(A
+. 3ra1e clearance is ad*usted to speciication 6drum.2. ydraulic %ra1e luid changed without spillage and illed at speciied level.. 3leeding the hydraulic system is perormed according to the re;uired steps and
procedure.4. Ad*usting %ra1e pedal pre0play is conducted as per speciication.5. Emergency %ra1e is ad*usted as per speciication, steps and procedure.
. /ersonal saety procedure is o%served through0out the *o%.7. 3ra1e system lin1ages chec1ed as per steps and procedure.". 3ra1e lines is properly chec1ed and without lea1s and %ent.$. #hec1ing slave and master cylinder is perormed according to steps and procedures.+!. /ower %ooster condition is chec1ed according to the re;uired steps and procedures.++. #hec1ing wheel cylinder?caliper is perormed accurately.+2. /ersonal saety procedure is o%served throughout the activity.+. A3S voltage is chec1ed as per speciication.+4. 'luid pressure chec1ed as speciied.+5. Amperage draw is chec1ed according to the re;uired manuacturer@s speciication.+. Testing and chec1ing wiring circuit are perormed accurately.
+7. Csed appropriate tools and e;uipment.+". Apply personal, vehicle and wor1shop saety procedure.
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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DCAL('(#AT(= Automotive Servicing NC II C=(T ' #M/ETE=#> Service Brake System
M)CLE T(TLE Servicing Brakes
LEAR=(=& CT#ME F+ $er)orm 1rake system *reventive maintenance
ASSESSME=T #R(TER(A
+. 'unction o %ra1es e-plained
2. #omponent o hydraulic %ra1e identiied.
. /rinciple o operation o hydraulic %ra1e e-plained.
4. Types o %ra1es e-plained and classiied.
RESCR#ES
Code No.
ALT723314Servicing Brakes
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EARNING E7$ERIENCES 8 ACTIVITIES
O9 - : $er)orm 1rake system *reventive maintenance
LEAR=(=& A#T(G(T(ES S/E#(AL (=STRC#T(=S
0 Ad*ust %ra1e clearance to speciication
0 Techni;ue in changing and illing luid tomaster cylinder
0 Steps and procedure in %leeding hydraulic%ra1es.
0 Ad*ust pedal ree0play
0 Ad*ust emergency %ra1es lin1age 0 'a%ricate and replace %ra1e lines.
0 Automotive Encyclopedia
0 /reventive and%oo1 0 3osch and%oo1 0 Today@s Technician
0 (L Learning Element Maintenance
0 Speciication Manual
Code No.
ALT723314Servicing Brakes
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IN!ORMATION S;EET NO( O9-&-
A+
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4. #lean 3ra1e )rum and Shoes
#lean the %ra1e shoe and lining withsand paper to remove stain oil cleanalso the %ra1e drum and %a1ing plate.
5. #hec1 wheel cylinder or lea1
=ote verhaul ( ound lea1 . #hec1 also or aulty retracting spring,
loose carrier or ancetor plate, sel ad*uster not operating.
7. Assem%le drum to %ac1ing plate and
tires and locate ad*usting hole at %ac1o %ac1ing plate or at the drum.
". Ad*ust the Shoe clearance a. Csing the %ra1e ad*usting tool, turn
the ad*uster until the wheel can nolonger %e rotated.
%. Turn the ad*uster slowly, notch %ynotch until the wheel can %erotated.
=ote )epress the pedal occasionally.
c. Repeat step 6% until the wheelsrotate slowly with a slight drag.
$. )rive test new ad*usted %ra1e. Rear %ra1e must react together.
Code No.
ALT723314Servicing Brakes
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#hec1 luid level and reilling +. #hec1 luid level
( Reservoir is plastic the level should%e %etween ma- and min or mm or top or reservoir.
2. Add 'luid i necessary.
(mportant)o not let the reservoir run empty.#hec1 the level re;uently.
=ote )o not allow luid to scatter at
any car parts especially on paintedparts. 3ra1e luid will destroy your car parts.
3leeding ydraulic 3ra1e 6Manual +. Raise the vehicle wheel.
The wheel cylinder that is arthest romthe master cylinder 6Rear Right 8heel
2. Remove %leeder plug cap rom the
%leeder screw or plug . #onnect a Transparent hose to the
%leeder plug and insert the other end ina hal ull container o resh luid.
=ote one end o the tu%e must %e
su%merge in the luid to prevent air rom entering the system.
4. /ump the %ra1e.
/edal several limes6this (s done %y the assistant
5. 8hile tile pedal is depressed, loosenthe %leeder plug a%out J0 turn to allowluid to low.
Code No.
ALT723314Servicing Brakes
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. Keep on pumping the pedal until%u%%les are drained
7. Add new luid to reservoir
(mportant)o not let the reservoir run empty.#hec1 the level re;uently
A+
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7. Slightly push the %ra1e pedal with your inger until it meets resistance
". Measure pedal stro1e reer tospeciication
+!.Tighten loc1 nut and measure againuntil pedal ree play is correct
++. Start engine and conirm i ree play iscorrect.
Emergency Brake8$arking Brake
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+. Set par1ing %ra1e to a ully appliedposition
2. Raise car and ma1e sure its securewheel should not rotate due to no. ( i wheel rotate proper ad*ustments must%e made.
. Released par1ing %ra1e, loosen
ad*ustment loc1 nut ad*ust nut until tirecannot %e rotated4. 8hen you can no longer turn the
wheels %y hand stop tightening
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5. Ad*ust ad*usting nut until wheels turnswith only a slight drag.
. #hec1 ca%les or raying, %rea1ageand deterioration
7. Spray all e-posed metals with
penetrating oils.
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ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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". #lean o threaded areas and ma1esure the tightening nuts are notdamage
$. Lower the vehicles and releasepar1ing %ra1es.
!a1ricating an+ Re*,acing Brake ines
(nspecting 3ra1e Line Tu%ing
#hec1 or %end, lea1age, rupture and1in1s.
=ote 8hen replacing a %ra1e line aalways used steel piping to withstandhigh pressure and corrosion
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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+. Cse recommended steel tu%e si
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5. /lace tu%e nut in correct direction.
. /lace tu%e in laring %ar with the endprotruding slightly a%ove the ace othe %ar.
7. 'irmly clamp the tu%e in the %ar so theorce e-erted during laring does notpush the tu%ing down through the %ar.
". To old over the end o the tu%ingplace adaptor or anvil in place overthe tu%e opening.
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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$. Tighten down the laring clamp.
+!.Loosen laring clamp and chec1 to seethat the end o the tu%ing is properly%elled.
++. (nstall the cone onto the tu%e openingand retighten laring clamp.
+2.The cone completes the dou%le lare%y olding the tu%ing %ac1 on itsel.This dou%les its thic1ness and createtwo sealing suraces.
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Date: Developed Date: Revised Page #
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+.3end the replacement tu%e to matchthe original tu%e using tu%ing %ender.
+4.#lean %ra1e tu%ing %y lushing it withclean %ro1e luid.
+5.(nstall the replace %ra1e tu%e,maintaining ade;uate clearance tometal edges and moving or vi%ratingparts.
+. (nstall %ra1e tu%e and tighten tu%enuts to speciication.
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ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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+7.3leed the hydraulic system
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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DCAL('(#AT(= Automotive Servicing NC II C=(T ' #M/ETE=#> Service Brake System
M)CLE T(TLE Servicing Brakes
LEAR=(=& CT#ME F2 'iagnose 1rake system )ai,ure
ASSESSME=T #R(TER(A
+. 3ra1e system lin1ages chec1ed as per steps and procedure.2. 3ra1e lines is properly chec1ed and without lea1s and %ent.. #hec1ing slave and master cylinder is perormed according to steps and procedures.4. /ower %ooster condition is chec1ed according to the re;uired steps and procedures.5. #hec1ing wheel cylinder?caliper is perormed accurately.. /ersonal saety procedure is o%served throughout the activity.
RESCR#ES
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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EARNING E7$ERIENCES 8 ACTIVITIES
O9 " : 'iagnose 1rake system )ai,ure
LEAR=(=& A#T(G(T(ES S/E#(AL (=STRC#T(=S
0 Trou%leshoot 3ra1e System
0 Automotive Encyclopedia
0 /reventive and%oo1 Maintenance
0 3osch and%oo1 0 Today@s Technician 0 (L Learning Element 0 Speciication Manual
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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IN!ORMATION S;EET NO( O9":-
TROUBES;OOTING BRAKES
E>cessive $e+a, Trave,+. Air in %ra1e lines.2. 'luid lea1.. 'aulty automatic ad*usters.
4. Malad*usted master cylinder push rod.5. 8orn drum %ra1e lining.. 'luid %ypassing ;uic1 ta1e0up valve to
reservoir.7. /artial %ra1e system ailure. E>cessive $e+a, E))ort+. &la
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Brakes S?ueak+. 8orn out %ra1e lining.2. &la
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DCAL('(#AT(= Automotive Servicing NC II C=(T ' #M/ETE=#> Service Brake System
M)CLE T(TLE Servicing Brakes
LEAR=(=& CT#ME F $er)orm ABS com*onent testing
ASSESSME=T #R(TER(A
+. A3S voltage is chec1ed as per speciication.
2. 'luid pressure chec1ed as speciied.
. Amperage draw is chec1ed according to the re;uired manuacturer@s speciication.
4. Testing and chec1ing wiring circuit are perormed accurately.
5. Csed appropriate tools and e;uipment.
. Apply personal, vehicle and wor1shop saety procedure.
RESCR#ES
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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EARNING E7$ERIENCES 8 ACTIVITIES
O9 0 : $er)orm ABS com*onent testing
LEAR=(=& A#T(G(T(ES S/E#(AL (=STRC#T(=S
0 Test A3S component
a. ydraulic unit %. Electrical System c. 8heel Speed Sensor d. E#C
0 Automotive Encyclopedia
0 /reventive and%oo1 0 Today@s Technician
0 (L Learning Element Maintenance
0 Speciication Manual
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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IN!ORMATION S;EET NO( O90:-
ANTI&OCK BRAKE S%STEM
A=T(0L#K 3RAKE 8AR=(=& L(&T
The A3S warning light is located in the instrument panel warning light cluster. ( it illuminateswhile driving, it indicates that there is a pro%lem in the A3S.
N A past ailure is indicated one time, each time the engine is started. The lash pattern is thesame as the warning light indication mode.
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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'IAGNOSIS
SE! TEST CO'ES
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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$ER!ORMANCE TEST
earners Name 'ate
Com*etency Service Brake SystemTest Attem*t
-st "n+ 0r+
'irections
CA INSTRUCTOR6 askinstructor to assessyour *er)ormance in t5e)o,,o=ing critica, taskan+ *er)ormance criteria1e,o=(
%ou =i,, 1e rate 1ase+ on
t5e overa,, eva,uation ont5e rig5t si+e(
OVERA EVAUATION
eve,Ac5ieve+ $ER!ORMANCE EVES
4 O #an perorm this s1ill without supervision and with initiativeand adapta%ility to pro%lem situations.
O #an perorm this s1ill satisactorily without assistance or supervision.
2 O #an perorm this s1ill satisactorily %ut re;uires someassistance and?or supervision.
+ O #an perorm parts o this s1ill satisactorily, %ut re;uires
considera%le assistance and?or supervision.
Instructor =i,, initia, ,eve, ac5ieve+(
$ER!ORMANCE STAN'AR'S!or acce*ta1,e ac5ievement6 a,, items s5ou,+ receive a %es2or N8A2 res*onse(
%es No N8A
+. ad*ust %ra1e clearance, according tospeciication
2. change and ill luid to master cylinder
. %leed hydraulic %ra1es
4. trou%leshoot, a%ricate and replace%ra1e lines
5. ad*ust emergency %ra1es lin1age
. test the ollowing A3S componenta. hydraulic unit
%. electrical systemc. wheel speed sensor d. E#C
7. ad*ust pedal ree0play according tospeciication
". proper use o tools and materials
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
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earners +iary
DIARY NOTES
Record important dates, jobs undertaken and other workplace eents that will assist !ou in proidin"
#urther details to an Assessor$
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Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
Nov. 28, 2003 a!" 1, 200$ 26
8/21/2019 Servicing Brakes
30/33
Recor+ o) Ac5ievement
Servicing Brake System
Learning utcome F+ 0 $er)orm 1rake system *reventive maintenance
/erormance #riteria
+. 'unction o %ra1es e-plained
2. #omponent o hydraulic %ra1e identiied.
. /rinciple o operation o hydraulic %ra1e e-plained.
4. Types o %ra1es e-plained and classiied.
#MME=TSPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPP
Learner has satisied the a%ove perormance criteria.
Learner@s signature PPPPPPPPPPPPPPP.
Trainer@s signature PPPPPPPPPPPPPPP..
)ate PPPPPPPPPPPPPPPPPPPPP.
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
Nov. 28, 2003 a!" 1, 200$ 27
8/21/2019 Servicing Brakes
31/33
Recor+ o) Ac5ievement
Servicing Brake System
Learning utcome F2 0 'iagnose 1rake system )ai,ure
/erormance #riteria
+. 3ra1e system lin1ages chec1ed as per steps and procedure.2. 3ra1e lines is properly chec1ed and without lea1s and %ent.. #hec1ing slave and master cylinder is perormed according to steps and
procedures.4. /ower %ooster condition is chec1ed according to the re;uired steps and
procedures.5. #hec1ing wheel cylinder?caliper is perormed accurately.. /ersonal saety procedure is o%served throughout the activity.
#MME=TSPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPP
Learner has satisied the a%ove perormance criteria.
Learner@s signature PPPPPPPPPPPPPPP.
Trainer@s signature PPPPPPPPPPPPPPP..
)ate PPPPPPPPPPPPPPPPPPPPP.
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
Nov. 28, 2003 a!" 1, 200$ 28
8/21/2019 Servicing Brakes
32/33
Recor+ o) Ac5ievement
Servicing Brake System
Learning utcome F 0 Perform ABS component testing
/erormance #riteria
+. A3S voltage is chec1ed as per speciication.2. 'luid pressure chec1ed as speciied.. Amperage draw is chec1ed according to the re;uired manuacturer@s
speciication.4. Testing and chec1ing wiring circuit are perormed accurately.5. Csed appropriate tools and e;uipment.. Apply personal, vehicle and wor1shop saety procedure.
#MME=TSPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
PPPPPPPPPPPPPPPPPPPPPPPPP
Learner has satisied the a%ove perormance criteria.
Learner@s signature PPPPPPPPPPPPPPP.
Trainer@s signature PPPPPPPPPPPPPPP..
)ate PPPPPPPPPPPPPPPPPPPPP.
Code No.
ALT723314Servicing Brakes
Date: Developed Date: Revised Page #
Nov. 28, 2003 a!" 1, 200$ 29
8/21/2019 Servicing Brakes
33/33
ACKNO@E'GEMENT
#opyright TES'A#ente- RT# G( Q Talisay
!irst $u1,is5e+ #T3ER 2!!
T5is +ra)t =as *re*are+ at t5e Com*etency&Base+ earning Materia,s'eve,o*ment @orks5o* con+ucte+ at t5e Cagayan +e Oro 3Bugo4 Sc5oo, o) Arts DTra+es6 )rom "0r+ to "/t5 Octo1er "0(
It =as 1ase+ on t5e com*etency stan+ar+ )or Automotive Service Tec5nician+eve,o*e+ 1y t5e Ski,, Stan+ar+ an+ Certi)ication O))ice 3SSCO46 an+ t5eCom*etency&Base+ Curricu,um Instructiona, Mo+u,es +eve,o*e+ 1y t5e Nationa,Institute )or Tec5nica, Vocationa, E+ucation an+ Training 3NITVET46 Tec5nica,E+ucation an+ Ski,,s 'eve,o*ment Aut5ority 3TES'A4(
Some materia,s )or conte>tua, ,earning 3science6 mat5 an+ communication4 =eresu**,ie+ 1y Aca+emic Teac5ers(
This learning instrument was developed %y the ollowing personnel
Technology (nstructors
Academic Teachers
Gocational (nstitution Supervisor
'acilitator
This wor1 was produced with unding provided %y TES)A.
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