Overhaul braking system components (heavy)

This unit covers the competence required to carry out an overhaul to hydraulic, mechanical, vacuum and power assisted, and electric heavy braking system components.


The unit includes identification and confirmation of the work requirement, preparation for work, overhauling of braking system components, conducting of serviceability tests on components, preparing brake components for use or storage and completion of work finalisation processes, including clean-up and documentation.

This unit of competence applies to heavy vehicles, trailers and towable equipment.

Work requires individuals to demonstrate some judgement and problem-solving skills in managing own work activities and contributing to a productive team environment.

Work is carried out in accordance with award provisions.

Elements and Performance Criteria



1. Prepare to overhaul braking system components

1.1. Nature and scope of the work requirements are identified and confirmed

1.2. OH&S requirements, including individual State/Territory regulatory requirements and personal protection needs are observed throughout the work

1.3. Procedures and information such as workshop manuals, specifications and tooling, are sourced

1.4. Method options are analysed and those most appropriate to the circumstances are selected and prepared

1.5. Technical and/or calibration requirements for overhaul are sourced and support equipment is identified and prepared

1.6. Warnings in relation to working with stored energy as in emergency braking actuators are observed

1.7. Dangers working with brake dust and preventative measures are observed

2. Overhaul braking system components

2.1. Information is accessed and interpreted from manufacturer/component supplier specifications

2.2. Braking system components are overhauled using approved methods, equipment and materials, in accordance with manufacturer/component supplier specifications

2.3. Overhaul of braking system components/sub assemblies is completed without causing damage to any component or system

2.4. All braking systems component overhaul activities are carried out according to industry regulations/guidelines, OH&S legislation, legislation and enterprise procedures/policies

3. Conduct serviceability tests on components

3.1. Methods for the conduct of the test is implemented in accordance with workplace procedures and manufacturer/component supplier specifications

3.2. Observations on the performance of the component is noted during the test

3.3. A determination is made as to the serviceability of the component

3.4. Failed components are tagged for rework

3.5. Documentation of observations are completed

4. Prepare brake components for use or storage

4.1. Inspection is made to ensure safety features are in place

4.2. Final inspection is made to ensure work is to workplace expectations

4.3. Brake component is presented for use or stored to workplace expectations

4.4. Job card is processed in accordance with workplace procedures

Required Skills

Required skills

apply research and interpretive skills sufficient to locate, interpret and apply manufacturer/component supplier procedures, workplace policies and procedures

apply analytical skills required for identification and analysis of technical information

apply plain English literacy and communication skills in relation to dealing with customers and team members

apply questioning and active listening skills for example when obtaining information from customers

apply oral communication skills sufficient to convey information and concepts to customers

apply planning and organising skills to work activities, including making good use of time and resources, sorting out priorities and monitoring own performance

interact effectively with other persons both on a one-to-one basis and in groups, including understanding and responding to the needs of a customer and working effectively as a member of a team to achieve a shared goal

use mathematical ideas and techniques to calculate time, assess tolerances, apply accurate measurements, calculate material requirements and establish quality checks

the capacity to apply problem-solving strategies in purposeful ways, both in situations where the problem and desired solution are clearly evident and in situations requiring critical thinking and a creative approach to achieve an outcome

use workplace technology related to the overhaul of heavy vehicle braking systems, including the use of specialist tooling and equipment, measuring equipment, computerised technology and communication devices and reporting/documenting of results

Required knowledge

A working knowledge of:

OH&S regulations/requirements, equipment, material and personal safety requirements

health hazards working with brake dust

hydraulic principles

operating principles of heavy braking systems and their components, including air compressors

overhaul procedures

test procedures

enterprise quality procedures

work organisation and planning processes

Evidence Required

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

It is essential that competence in this unit signifies ability to transfer competence to changing circumstances and to respond to unusual circumstances in the critical aspects of:

observing safety procedures and requirements

communicating effectively with others involved in or affected by the work

selecting methods and techniques appropriate to the circumstances

completing preparatory activity in a systematic manner

conducting the overhaul of a range of braking system components in accordance with workplace and manufacturer/component supplier requirements

interpreting test results

completing the work within workplace timeframes

presentation/storage of brake components in compliance with workplace requirements

Context of, and specific resources for assessment

Application of competence is to be assessed in the workplace or simulated worksite

Assessment is to occur using standard and authorised work practices, safety requirements and environmental constraints

Assessment is to comply with regulatory requirements, including Australian Standards

The following resources should be made available:

workplace location or simulated workplace

materials relevant to the overhaul of heavy vehicle braking systems

equipment, hand and power tooling appropriate to the overhaul of heavy vehicle braking systems

activities covering the mandatory task requirements

specifications and work instructions

Method of assessment

Assessment must satisfy the endorsed assessment guidelines of the automotive industry's RS&R Training Package

Assessment methods must confirm consistency and accuracy of performance together with application of underpinning knowledge

Assessment must be by direct observation of tasks, with questioning on underpinning knowledge and it must also reinforce the integration of key competencies

Assessment may be applied under project related conditions (real or simulated) and require evidence of process

Assessment must confirm a reasonable inference that competence is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances

It is preferable assessment reflects a process rather than an event and occurs over a period of time to cover the varying quality circumstances. Evidence of performance may be provided by customers, team leaders/members or other appropriate persons subject to agreed authentication arrangements

Competence in this unit may be assessed in conjunction with other functional units which together form part of the holistic work role

Guidance information for assessment

Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Actuating mechanisms

Actuating mechanisms may include fluid operated, mechanically operated, power assisted, anti-lock brake systems, computer systems

System components

System components may include disc pads, master cylinders, brake shoes, brake callipers, brake hoses, brake actuators, mechanical devices, and hydraulic and pneumatic valves

Overhaul methods and sequences

Overhaul methods and sequences are to include the complete dismantling of component parts, measuring and evaluation of wear, the replacement, repair, rebuilding or reconditioning of parts comparable to original parts, the assembly of parts, performance of functional testing and the completion of records


OH&S requirements are to be in accordance with legislation/regulations/codes of practice and enterprise safety policies and procedures. This may include protective clothing and equipment, use of tooling and equipment, workplace environment and safety, handling of materials, use of fire fighting equipment, enterprise first aid, hazard control and hazardous materials and substances

Personal protective equipment

Personal protective equipment is to include that prescribed under legislation/regulations/codes of practice and workplace policies and practices

Safe operating procedures

Safe operating procedures are to include, but are not limited to the conduct of operational risk assessment and treatments associated with vehicular movement, toxic substances, electrical safety, machinery movement and operation, manual and mechanical lifting and shifting, working in proximity to others and site visitors

Emergency procedures

Emergency procedures related to this unit are to include, but are not limited to emergency shutdown and stopping of equipment, extinguishing fires, enterprise first aid requirements and site evacuation

Environmental requirements

Environmental requirements are to include but are not limited to waste management, noise, dust and clean-up management

Quality requirements

Quality requirements are to include, but are not limited to regulations, including Australian Standards, internal company quality policy and standards and enterprise operations and procedures

Statutory/regulatory authorities

Statutory/regulatory authorities may include Federal, State/Territory and local authorities administering acts, regulations and codes of practice

Tooling and equipment

Tooling and equipment may include hand tooling, power tooling, specialist tooling for removal/adjustment, lifting and supporting equipment, brake dust extraction equipment, measuring instruments and overhaul machining equipment


Materials may include spare parts, lubricants and cleaning materials


Communications are to include, but are not limited to verbal and visual instructions and fault reporting and may include site specific instructions, written instructions, plans or instructions related to job/task, telephones and pagers


Sources of information/documents may include:

verbal or written and graphical instructions, signage, work schedules/plans/specifications, work bulletins, memos, material safety data sheets, diagrams or sketches

safe work procedures related to the overhaul of heavy vehicle braking systems

regulatory/legislative requirements pertaining to the automotive industry, including Australian Design Rules

engineer's design specifications and instructions

organisation work specifications and requirements

instructions issued by authorised enterprise or external persons

Australian Standards


Unit sector


Employability Skills

This unit contains employability skills.

Licensing Information

Not Applicable