DPE 4010 - Brakes

Students will:

• Identify and practice general shop safety rules and procedures.
• Utilizing safe procedures for handling of tools and equipment.
• Identifying and using proper placement of floor jacks and jack stands.
• Identifying and using proper procedures for safe lift operation.
• Utilizing proper ventilation procedures for working within the lab/shop area.
• Identifying marked safety areas.
• Identifying the location and the types of fire extinguishers and other fire safety equipment.
• Demonstrating knowledge of the procedures for using fire extinguishers and other fire safety equipment.
• Identifying the location and use of eye wash stations.
• Identifying the location of the posted evacuation routes.
• Complying with the required use of safety glasses, ear protection, gloves, and shoes during lab/shop activities.
• Identifying and wearing appropriate clothing for lab/shop activities.
• Securing hair and removing jewelry for lab/shop activities.
• Demonstrating awareness of the safety aspects of supplemental restraint systems (SRS), electronic brake control systems, and hybrid vehicle high voltage circuits.
• Demonstrating awareness of the safety aspects of high voltage circuits (such as high intensity discharge (HID) lamps, ignition systems, injection systems, etc.).
• Locating and demonstrating knowledge of material safety data sheets (MSDS).

Tools and Equipment

• Identify tools and their usage in automotive applications.
• Identifying standard and metric designation.
• Demonstrating safe handling and use of appropriate tools.
• Demonstrating proper cleaning, storage, and maintenance of tools and equipment.
• Demonstrating proper use of precision measuring tools Examples: micrometer, dial-indicator, dial-caliper

Air Brakes Supply and Service Systems

• Identify poor stopping, air leaks, premature wear, pulling, grabbing, dragging, or balance problems caused by supply and service system malfunctions; determine needed action.
• Check air system build-up time; determine needed action.
• Drain air reservoir/tanks; check for oil, water, and foreign material; determine needed action.
• Inspect air compressor drive gear, belts and coupling; adjust or replace as needed.
• Inspect air compressor inlet. Inspecting oil supply and coolant lines, fittings, and mounting brackets; repair or replace as needed.
• Inspect and test air system pressure controls: governor, unloader assembly valves, filters, lines, hoses, and fittings; adjust or replace as needed.
• Inspect air system lines, hoses, fittings, and couplings; repair or replace as needed.
• Inspect and test air tank relief (safety) valves, one-way (single) check valves, two-way (double) check valves, manual and automatic drain valves; replace as needed.
• Inspect and clean air drier systems, filters, valves, heaters, wiring, and connectors; repair or replace as needed.
• Inspect and test brake application (foot/treadle) valve, fittings, and mounts; check pedal operation; replace as needed.
• Inspect and test stop light circuit switches, wiring, and connectors; repair or replace as needed.
• Inspect and test hand brake (trailer) control valve, lines, fittings, and mountings; repair or replace as needed.
• Inspect and test brake relay valves; replace as needed.
• Inspect and test quick release valves; replace as needed.
• Inspect and test tractor protection valve; replace as needed.
• Inspect and test emergency (spring) brake control/modulator valve(s); replace as needed.
• Inspect and test low pressure warning devices, wiring, and connectors; repair or replace as needed.
• Inspect and test air pressure gauges, lines, and fittings; replace as needed.

Air Mechanical/Foundation Brakes

• Identify poor stopping, brake noise, premature wear, pulling, grabbing, or dragging problems caused by the foundation brake, slack adjuster, and brake chamber problems; determine needed action.
• Inspect and test service brake chambers, diaphragm, clamp, spring, pushrod, clevis, and mounting brackets; repair or replace as needed.
• Identify type, inspect and service slack adjusters; perform needed action.
• Inspect camshafts, tubes, rollers, bushings, seals, spacers, retainers, brake spiders, shields, anchor pins, and springs; replace as needed.
• Inspect, clean, and adjust air disc brake caliper assemblies; determine needed repairs.
• Inspect and measure brake shoes or pads; perform needed action.
• Inspect and measure brake drums or rotors; perform needed action.

Air Parking Brakes

• Inspect and test parking (spring) brake chamber diaphragm and seals; replace parking (spring) brake chamber; dispose of removed chambers in accordance with local regulations.
• Inspect and test parking (spring) brake check valves, lines, hoses, and fittings; replace as needed.
• Inspect and test parking (spring) brake application and release valve; replace as needed.
• Manually release (cage) and reset (uncage) parking (spring) brakes in accordance with manufacturers’ recommendations.
• Identify and test anti compounding brake function.

Hydraulic Brake System

• Identify poor stopping, premature wear, pulling, dragging, balance, or pedal feel problems caused by the hydraulic system; determine needed action.
• Inspect and test master cylinder for internal/external leaks and damage; replace as needed.
• Inspect hydraulic system brake lines, flexible hoses, and fittings for leaks and damage; replace as needed.
• Inspect and test metering (hold-off), load sensing/proportioning, proportioning, and combination valves; replace as needed.
• Inspect and test brake pressure differential valve and warning light circuit switch, bulbs/LEDs, wiring, and connectors; repair or replace as needed.
• Inspect disc brake caliper assemblies; replace as needed.
• Inspect/test brake fluid; bleed and/or flush system; determine proper fluid type.

Hydraulic Mechanical/Foundation Brakes

• Identify poor stopping, brake noise, premature wear, pulling, grabbing, dragging, or pedal feel problems caused by mechanical components; determine needed action.
• Inspect and measure rotors; perform needed action.
• Inspect and measure disc brake pads; inspect mounting hardware; perform needed action.
• Check parking brake operation; inspect parking brake application and holding devices; adjust and replace as needed.

Hydraulic Power Assist Units

• Identify stopping problems caused by the brake assist (booster) system; determine needed action.
• Inspect, test, repair, or replace hydraulic brake assist (booster), hoses, and control valves; determine proper fluid type.
• Check emergency (back-up, reserve) brake assist system.

Air and Hydraulic Antilock Brake Systems (ABS) and Automatic Traction Control (ATC)

• Observe antilock brake system (ABS) warning light operation (includes trailer and dash mounted trailer ABS warning light); determine needed action.
• Diagnose antilock brake system (ABS) electronic control(s) and components using self-diagnosis and/or electronic service tool(s); determine needed action.
• Identify poor stopping and wheel lock-up problems caused by failure of the antilock brake system (ABS); determine needed action.
• Test and check operation of antilock brake system (ABS) air, hydraulic, electrical, and mechanical components; perform needed action.
• Test antilock brake system (ABS) wheel speed sensors and circuits; adjust or replace as needed.
• Bleed the ABS hydraulic circuits.
• Observe automatic traction control (ATC) warning light operation; determine needed action.
• Diagnose automatic traction control (ATC) electronic control(s) and components using self-diagnosis and/or specified test equipment (scan tool, PC computer); determine needed action.
• Verify power line carrier (PLC) operations.

Wheel Bearings

• Clean, inspect, lubricate, and replace wheel bearings and races/cups; replace seals and wear rings; inspect spindle/tube; inspect and replace retaining hardware; adjust wheel bearings. Verify end play with dial indicator method.
• Identify, inspect, or replace unitized/preset hub bearing assemblies.