Servicing Brakes

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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

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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

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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.

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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.

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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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". #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

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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.

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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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+.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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+7.3leed the hydraulic system

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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

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O9 " : 'iagnose 1rake system )ai,ure


0 Trou%leshoot 3ra1e System


0 /reventive and%oo1 Maintenance

0 3osch and%oo1 0 Today@s Technician 0 (L Learning Element 0 Speciication Manual

Code No.



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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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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.



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O9 0 : $er)orm ABS com*onent testing


0 Test A3S component

a. ydraulic unit %. Electrical System c. 8heel Speed Sensor d. E#C


0 /reventive and%oo1 0 Today@s Technician

0 (L Learning Element Maintenance

0 Speciication Manual

Code No.



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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.

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'IAGNOSIS

SE! TEST CO'ES

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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

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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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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











PPPPPPPPPPPPPPPPPPPPPPPPP

Learner has satisied the a%ove perormance criteria.

Learner@s signature PPPPPPPPPPPPPPP.

Trainer@s signature PPPPPPPPPPPPPPP..

)ate PPPPPPPPPPPPPPPPPPPPP.

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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.


















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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.


















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ACKNO@E'GEMENT

#opyright TES'A#ente- RT# G( Q Talisay

!irst $u1,is5e+ #T3ER 2!!

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