AURHTB003
Overhaul hydraulic and air over hydraulic braking system components


Application

This unit describes the performance outcomes required to return hydraulic and air over hydraulic braking system components to original manufacturer tolerances and clearances. It involves preparing for the task, dismantling and evaluating the braking system components, carrying out the overhaul procedures, reassembling and testing the braking system components, and completing workplace processes and documentation.

It applies to those working in the automotive service and repair industry. The braking systems include those of agricultural machinery, heavy commercial vehicles or mobile plant machinery.

No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.


Elements and Performance Criteria

Elements

Elements describe the essential outcomes.

Performance Criteria

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.

1. Prepare to dismantle braking system components

1.1 Job requirements are determined from workplace instructions

1.2 Dismantling information is sourced and interpreted

1.3 Dismantling options are analysed and those most appropriate to the circumstances are selected

1.4 Hazards associated with the work are identified and risks are managed

1.5 Dismantling tools and equipment are selected and checked for serviceability

2. Dismantle and evaluate braking system and components

2.1 Braking system is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements, and without causing unnecessary damage to components or systems

2.2 Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements

2.3 Components are measured and compared with manufacturer specifications and serviceability is determined

2.4 Component repair method is determined

2.5 Unserviceable parts are identified and replacement parts sourced

3. Carry out overhaul

3.1 Overhaul information is sourced and interpreted

3.2 Overhaul options are analysed and those most appropriate to the circumstances are selected

3.3 Overhaul tools and equipment are selected and checked for serviceability

3.4 Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems

4. Assemble components

4.1 Braking system components are assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements

4.2 Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made

4.3 Assembly of braking system components is completed within workplace timeframes and without causing damage to other components or systems

4.4 Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified

5. Complete work processes

5.1 Final inspection is made to ensure work is to workplace expectations and braking system components are presented ready for use or storage

5.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

5.3 Tools and equipment are checked and stored according to workplace procedures

5.4 Workplace documentation is processed according to workplace procedures

Evidence of Performance

Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:

overhaul the following hydraulic and air over hydraulic braking system components:

two different wheel end disc and drum brake components

two different hydraulic system components

two different air system components.


Evidence of Knowledge

Individuals must be able to demonstrate knowledge of:

workplace health and safety (WHS) and occupational health and safety (OHS) requirements relating to overhauling hydraulic and air over hydraulic braking system components, including procedures for:

operating specialised braking system component overhaul tools, equipment and machinery

using chemicals and toxic substances

operating manual and mechanical lifting equipment

working with stored energy

environmental requirements, including procedures for trapping, storing and disposing of oils and fluids released from braking systems

types, characteristics and operating principles of hydraulic and air over hydraulic braking systems and associated components, including:

disc and drum wheel end systems

hydraulic systems

air systems

braking system overhaul procedures, including:

methods for cleaning and preparing braking system components for overhaul

braking system component dismantling procedures

braking system component inspection, measuring and evaluation procedures, including methods for measuring and calculating tolerances and clearances

braking system component repair and adjustment procedures, including:

brake actuators

air compressors

air storage and valves

disc and drum wheel end components

slack adjusters

master cylinder

brake booster

component assembly procedures, including procedures for measuring and calculating tolerances, and adjusting components

post-overhaul testing procedures for braking system components.


Assessment Conditions

Assessors must satisfy NVR/AQTF assessor requirements.

Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.

Assessment must include direct observation of tasks.

Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the hydraulic and air over hydraulic braking system components that they have worked on, e.g. repair orders.

Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.

The following resources must be made available:

automotive repair workplace or simulated workplace

workplace instructions

manufacturer hydraulic and air over hydraulic braking system component specifications

heavy vehicle braking system components specified in the performance evidence and requiring overhaul

tools, equipment and materials appropriate for overhauling and adjusting hydraulic and air over hydraulic braking system components.


Foundation Skills

This section describes those language, literacy, numeracy and employment skills that are essential to performance and are not explicit in the performance criteria.

Skills

Description

Learning skills to:

locate sources of information for braking system components efficiently.

Reading skills to:

interpret and assess information from manufacturer and workshop literature when seeking braking system component specifications and procedures.

Writing skills to:

legibly and accurately fill out workplace documentation when reporting diagnostic findings, making repair recommendations, and recording parts and material used.

Oral communication skills to:

clarify instructions, report evaluation findings and make overhaul recommendations.

Numeracy skills to:

measure braking system components and use basic mathematical operations, including addition, subtraction, multiplication and division, to calculate distances, areas, volumes, tolerances and deviations from manufacturer specifications.

Planning and organising skills to:

plan own work requirements and prioritise and sequence actions to achieve required outcomes and ensure tasks are completed within workplace timeframes.

Technology skills to:

use precision measuring equipment, such as vernier calipers and micrometers

use specialised braking system component overhaul equipment, such as brake discs and drum lathes.


Range Statement

This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.

Safety and environmental requirements must include:

work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for:

operating specialised braking system component overhaul tools, equipment and machinery

using chemicals and toxic substances

operating for manual and mechanical lifting equipment

working with stored energy

environmental requirements, including procedures for trapping, storing and disposing of oils and fluids released from braking systems.


Sectors

Technical - Brakes


Competency Field

Mechanical - Heavy Vehicle