Brakes Inspection Hydraulic Brakes

Transcription

1 Brakes Inspection Hydraulic Brakes Student/intern information: Name Date Class Vehicle used for this activity: Year Make Model Odometer VIN Learning Objective/Task 2007 NATEF Reference Number Check master cylinder fluid level and condition. 7-2D1 P-1 Inspect brake lines, fittings, flexible hoses, and valves for leaks and damage. Check parking brake operation; inspect parking brake application and holding devices. Check operation of hydraulic system: pedal travel, pedal effort, pedal feel (drift). 7-2D2 P-1 7-2D3 P-1 7-2D4 P-1 Inspect wheel cylinders/calipers for leakage and damage. 7-2D5 P-1 Inspect power brake booster(s), hoses, and check/control valves. 7-2D6 P-1 Inspect and record brake lining/pad condition and thickness. 7-2D7 P-1 Inspect and record condition of brake drums/rotors and adjust drum brakes as required. 7-2D8 P-1 Check antilock braking system (ABS) wiring and connectors. 7-2D9 P NATEF Priority Level Time off Time on Total time Recommended Resource Materials CDX Diesel: Preventive Maintenance and Inspection Technical service bulletins, shop manuals, and any other information applicable to the specific vehicle or components you are working on Class notes Materials Required Vehicle Vehicle manufacturer s workshop manual Manufacturer-specific tools, depending on the concern Vehicle lifting equipment, if applicable Diagnostic tools Electrical/electronic testing equipment Measuring equipment Workshop tools Hand tools Some Safety Issues to Consider Diagnosis of this fault may require test driving the vehicle on the school grounds or on a hoist, both of which carry severe risks. Attempt this task only with full permission from your supervisor/instructor and follow all the guidelines exactly. Caution: If you are working in an area where there could be brake dust present (may contain asbestos, which has been determined to cause cancer when inhaled or ingested), wear and use all OSHA-approved asbestos protective/removal equipment. Lifting equipment such as vehicle jacks and stands, vehicle hoists, and engine hoists are important tools that increase productivity and make the job easier. However, they can also cause severe injury or death if used improperly. Make sure you follow the manufacturer s operation procedures. Also make sure you have your supervisor/instructor s permission to use any particular type of lifting equipment. Comply with personal and environmental safety practices associated with clothing; eye protection; hand Brakes Inspection Hydraulic Brakes 1

2 tools; power equipment; proper ventilation; and the handling, storage, and disposal of chemicals/materials in accordance with federal, state, and local regulations. Always wear the correct protective eyewear and clothing and use the appropriate safety equipment, as well as fender covers, seat protectors, and floor mat protectors. Make sure you understand and observe all legislative and personal safety procedures when carrying out practical assignments. If you are unsure of what these are, ask your supervisor/instructor. Performance Standard 0 No exposure: No information or practice provided during the program; complete training required 1 Exposure only: General information provided with no practice time; close supervision needed; additional training required 2 Limited practice: Has practiced job during training program; additional training required to develop skill 3 Moderately skilled: Has performed job independently during training program; limited additional training may be required 4 Skilled: Can perform job independently with no additional training TASK Verify operator s concern, review past maintenance documents, and record condition on appropriate document. 7-2D1 7-2D9 1. Check master cylinder fluid level and condition. a. Locate brake master cylinder. b. Clean the top of the cylinder. c. Open master cylinder cap and check fluid level. Is it at the specified level? Yes: Requires top up: Time off Time on Total time d. Collect a sample of current brake fluid. e. Test the sample for contamination, etc.: Satisfactory: Requires changing: If requires changing: List recommendation(s): 2. Inspect brake lines, fittings, flexible hoses, and valves for leaks and damage. a. Inspect all brake lines, both solid and flexible, for condition and security: Yes: Require maintenance: If require maintenance: List areas and recommendation(s): b. Inspect brake valves for signs of external leakage: Yes: Require maintenance: If require maintenance: List areas and recommendation(s): 3. Check parking brake operation; inspect parking brake application and holding devices. a. Reference the manufacturer s workshop manual for the correct procedure for checking the parking brake operation. Brakes Inspection Hydraulic Brakes 2

3 b. Following the procedure from the workshop manual, check and inspect parking brake application, including holding devices: 4. Check operation of hydraulic system: pedal travel, pedal effort, and pedal feel (drift). Following the procedure from the workshop manual, check the operation of the hydraulic brake system: a. Test pedal travel and security: b. Test pedal effort: c. Check pedal free play (drift): 5. Inspect wheel cylinders/calipers for leakage and damage. With reference to the vehicle manufacturer s workshop manual, research the description and operation of the brake system for this vehicle, including the researching of drum/disc brake diagnostic procedure and wheel assembly and brake drum(s) removal/installation procedures: a. Discuss these findings with your instructor. b. If instructed by your instructor, carry out the inspection procedure. c. Check the wheel cylinder dust seal for signs of fluid leakage: Brakes Inspection Hydraulic Brakes 3

4 d. Check the disc brake caliper for signs of fluid leakage: 6. Inspect and record brake lining/pad condition and thickness and inspect and record the condition of the brake drums/rotors. a. Record the following information brake linings: Maximum drum diameter: in/mm Maximum drum out-of-round: in/mm Minimum lining thickness (primary): in/mm Minimum lining thickness (secondary): in/mm b. Are these measurements within specifications? Yes: No: If no: List the problem and your recommendation(s): c. Record the following information disc rotor and pads: Maximum rotor diameter: in/mm Maximum rotor out-of-round: in/mm Minimum pad thickness (outer): in/mm Minimum pad thickness (inner): in/mm d. Are these measurements within specifications? Yes: No: If no: List the problem and your recommendation(s): e. Refit the drum/pad(s) and wheel assembly in accordance with manufacturer s specifications. f. Ensure that the wheel lug nuts are torqued to manufacturer s specification and tightening sequence. g. Wheel lug nut torque: ft/lbs (N/m) h. Actual torque: ft/lbs (N/m) Brakes Inspection Hydraulic Brakes 4

5 7. Inspect power brake booster(s), hoses, and check/control valves. a. Inspect power booster(s) and all brake lines, both solid and flexible, for condition and security: b. Inspect power booster(s) and check/control valves operation: 8. Adjust drum brakes. a. Follow the procedural guide from the workshop manual and all OSHA safety requirements. b. Adjust all drum brakes as required. 9. Check antilock braking system (ABS) wiring and connectors for security and integrity. If requires maintenance: List areas and recommendations: 10. Discuss the finding(s) with the instructor. Performance Rating 2007 NATEF Reference Number: 7-2D1 7-2D Supervisor/instructor signature Date Brakes Inspection Hydraulic Brakes 5