COASTAL BEND COLLEGE AUTOMOTIVE TECHNOLOGY SYLLABUS (rev. Fall 2012)

Transcription

1 COASTAL BEND COLLEGE AUTOMOTIVE TECHNOLOGY SYLLABUS (rev. Fall 2012) AUMT 1310: Automotive Brake Systems SEMESTER HOURS: 3 TEXTBOOK Automotive Technology A systems Approach COURSE DESCRIPTION; Operation and repair of drum/ disc type brake systems. Emphasis on safe use of modern equipment. Topics include brake theory, diagnosis, and repair of power, manual, anti-lock brake systems, and parking brakes. COURSE LEARNING OUTCOMES: Utilizing appropriate safety procedures, the student will diagnose and repair hydraulic systems; diagnose and repair drum/ disc brake systems; diagnose and repair parking brakes; diagnose and repair anti-lock brake systems. PERFORMANCE OBJECTIVES: By the end of the semester, the student will be able to perform the following tasks in the lab and the classroom: 1. The student will demonstrate proper procedures involving the operation of an automotive shop to the standards of the industry and instructor. 2. The student will demonstrate knowledge of proper procedures of shop cleaning and toolroom care according to standards of the instructor and the Industrial Division. 3. The student will demonstrate knowledge of correct safety procedures in the automotive lab in accordance with shop safety and dress code standards. 4. The student will be able to identify the components of the automobile hydraulic brake system, explain each component's function, and make judgments and decisions in the diagnosing of brake failure. 5. The student will be able to recognize and identify disc brake malfunctions in preparation for correcting the brake systems..

2 6. The student will be able to recognize and identify drum brake malfunctions in preparation for correcting the brake systems.. 7. The student will be able to determine the need for bleeding a hydraulic brake system, select the proper tools and equipment, and select a method for bleeding brake. 8. The student will be able to accurately diagnose anti-lock brake malfunctions using appropriate methods in preparation for correcting the brake systems. COURSE OUTLINE: Brake Systems I. Friction A. Kinetic Friction B. Static Friction C. Factors Governing Braking 1. Pressure 2. Coeffceint of friction 3. Friction contact surface 4. Heat dissipation D. Brake Lining Friction Materials 1. Fully metallic 2. Semimetallic 3. Nonabestos II. Principles of Hydraulic Brake Systems A. Single braking systems B. Dual braking systems 1. Front/rear spit system 2. Diagonally-spit system III. Hydraulic Brake System Components A. Brake fluid B. Brake pedal C. Master cylinder 1. Single system master cylinder 2. Dual master cylinder IV. Master Cylinder Operation A. Master Cylinder Components 1. Reservoirs 2. Pistons 3. Cups 4. Ports 5. Residual chrck valve V. Hydraulic Tubes and Hoses A. Brake Line Tubing B. Fittings

3 C. Brake Line Hoses VI. Hydraulic System Safety Switches and Valves A. Pressure Differential (Warning Light) Switches B. Metering and Proportioning Valves 1. Metering valves 2. Proportioning valves a. Height sensing proportional valves 3. Combination valves 4. Three-function valves 5. Two-function valves C. Stop light switch VII. Drum and Disc Brake Assemblies A. Drum brakes B. Disc brakes 1. Rotor 2. Caliper VIII. Hydraulic System Service A. Brake Fluid Inspection B. System Flushing C. Brake Line Inspection D. Brake Pedal Inspection 1. Pedal reserve E. Master Cylinder Rebuilding F. Hydraulic System Bleeding 1. Manual bleeding 2. Pressure bleeding G. Power Brakes H. Vacuum-Assist Power Brakes I. Operation 1. Servicing vacuum-assist booster units 2. Pressure check 3. Pedal travel 4. Vacuum reading 5. Release problems 6. Hard pedal 7. Grabbing brakes 8. Check of internal binding IX. Pushrod Adjustment A. Gauge Method B. Air Method X. Hydraulic-Assist Power Booster A. Operation B. Basic Operational Test C. Accumulator Test D. Noise Troubleshooting A. Hydro-boost

4 B. Testing the hydro-boost 1. Basic operation test 2. Accumulator test 3. Noise troubleshooting C. Powermaster hydraulic booster 1. Pump 2. Accumulator 3. Master cylinder 4. Duel-master switch 5. Reservoir 6. Booster Drum Brakes I. Drum Brake Operation II. Drum Brake Components A. Wheel Cylinders B. Brake Shoes and Linings 1. Primary shoe 2. Secondary shoe C. Mechanical Components 1. Shoe return springs 2. Shoe hold-downs 3. Shoe anchors D. Drums II. Drum brake designs A. Duo-Servo Drum Brakes B. Automatically Adjusted Servo Brakes 1. Basic cable 2. Cable with overtravel spring 3. Lever with override 4. Lever and pawl C. Non-Servo Drum Brakes D. Automatically Adjusted Non-Servo Brakes 1. Automatic cam adjusters 2. Ratchet automatic adjuster E. Inspection and service 1. Brake noises IV. Road Testing Brakes V. Drum Brake Inspection A. Shoe and Lining Removal B. Drum Inspection 1. Scored drum surface 2. Bell-mouthed drum 3. Concave drum 4. Convex drum 5. Hards spots on the drum

5 6. Threaded drum surface 7. Heat cracks 8. Cracked drum 9. Out-of-round drums C. Drum measurments D. Drum refinishing E. Cleaning Newly Refaced Drums VI. Brake Shoes and Linings A. Brake Relining B. Sizing New Linings C. Lining Adjustment D. Drum Shoe and Brake Installation VII. Wheel Cylinder Inspection and Servicing A. Inspecting and Cleaning Wheel Cylinders B. Replacing Wheel Cylinders VIII. Drum Brake Parking Brakes A. Types of Parking Brake Systems IX. Integal Parking Brakes A. Adjusting and Replacing Parking Brakes 1. Testing Disc Brakes I. Disc Brake Components and Their Fuctions A. Hub and Rotor Assembly 1. Splash shield B. Caliper Assembly 1. Piston 2. Dust boot C. Fixed Caliper Disc Brakes D. Floating Caliper Disc Brakes E. Sliding Caliper Disc Brakes F. Brake Pad Assembly 1. Audible sensors G. Rear Disc/Drum (Auxiliary) Parking Brake H. Rear Disc Parking Brakes II. Disc Brake Diagnosis A. Warning Lights B. Pulsating Pedal C. Spongy Pedal D. Hard Pedal E. Dragging Brakes F. Grabbing Brakes G. Noise H. Pulling III. Service Precautions

6 IV. General Caliper Inspecting and Servicing A. Caliper Removal B. Brake Pad Removal C. Caliper Disassembly D. Loaded caliper E. Caliper Reassembly 1. Anti-squeal shim E. Brake Pad Installation 1. Fixed caliper brake pads 2. Sliding caliper brake pads 3. Floating caliper brake pads F. Caliper installation V. Rotor Inspecting and Servicing A. Lateral Runout B. Lack of Parallelism C. Scoring D. Bluing or Heat checking E. Rusty rotor F. Rotor Service ANTILOCK BRAKE SYSTEMS I. Antilock Brakes Systems A. Pressure Modulation B. Pedal Feel II. ABS Components A. Hydraulic Components 1. Accumulator 2. Antilock hydraulic control valve assembly 3. Booster jump 4. Booster/master cylinder assembly 5. Fluid accumulators 6. Hydraulic control unit 7. Main valve 8. Modulator unit 9. Solenoid valve 10. Valve block assembly 11. Wheel circuit valves B. Electrical/Electronic Components 1. ABS control module 2. Brake pedal sensor 3. Data link connector (DLC) 4. Diagnostic trouble code (DTC) 5. Indicator lights 6. Lateral acceleration sensor 7. Pressure switch 8. Pressure differential switch

7 9. Relay 10. Toothed ring 11. Wheel speed sensor III. Types of Antilock Brake Systems A. Integral B. Non-Integral C. Two-Wheel System 1. 1 channel 2. 2 channel D. Full (Four Wheel) Systems 1. 3 channel 2. 4 channel IV. ABS Operation A. Two-Wheel Systems (Non-Integral) B. Four-Wheel Systems(Non-Integral) 1. Modulator assembly 2. Self-diagnosis C. Four-Wheel Systems(Integral) D. Generals Motors Electromagnetic Antilock Brake Systems E. Other Brake Systems V. Automatic Traction Control VI. Automatic Stability Control VII. Antilock Brake System Service A. Safety Precautions B. Relieving Accumulator Pressure VIII. Diagnosis and Testing A. Pre-Diagnostic Inspection B. Visual Inspection C. Test Drive D. Self-Diagnosis E. Testers and Scan Tools F. Testing Components with ABS Scan Tools G. Testing Components with a Lab Scope H. Component Replacement 1. Wheel speed sensor 2. Brake system bleeding TEACHING METHODS: 1. Lecture 2. Discussion 3. Audio Visual Aids 4. Hand Outs 5. Hands On (Lab)

8 EVALUATION METHODS: 1. Written Exams 2. Classroom Participation 3. Lab Work 4. Safety Practices GRADING PROCEDURES: 1. Classroom (Test and Participation) 20% 2. Lab Project Completion and Safety 50% 3. Final Exam 30% ATTENDANCE POLICY: Fall and Spring Semesters: TWO absences will result in the loss of ONE letter grade Summer Semester: ONE absence will result in the loss of ONE letter grade REFERENCE MATERIAL: 1. Automotive Technology 2. College Library 3. Shop Publications 4. LAC (Learning Assistance Center) 5. Equipment operating manuals 6. Manufactures' Service Manuals