Columbus State Community College
Automotive and Applied Technologies Department
Automotive Technology
COURSE: AUTO 1150 Brake Systems: Theory and Operation
CREDITS: 2 CLASS HOURS PER WEEK: 3
PREREQUISITES: AUTO 1101 and AUTO
1106 and DEV 0155 or Placement into ENGL0190 or higher AND DEV 0115 or placement into
Math 1000 or higher
DESCRIPTION OF COURSE
This course presents the theory, operation, service, and repair of drum brakes, disc brakes,
hydraulic components, brake lines, and power brakes. Must have satisfactorily completed
AUTO 1101 and 1106. See plan of study or an Automotive Advisor for recommended course
sequence.
STUDENT LEARNING OUTCOMES
• Evaluate Rotors and Drums
• Inspect the Brake system
• R/R Duo-Servo and Leading Trailing Systems
• R/R Disc Brakes
• Service Brake System Hydraulics
• Explain the operation of the Brake System
GENERAL EDUCATION OUTCOMES
Columbus State Community College's general education outcomes are an integral part of the
curriculum and central to the mission of the college. The faculty at Columbus State has
determined that these outcomes include the following competencies:
•
Critical Thinking
•
Quantitative Literacy
•
Scientific and Technological Effectiveness
•
Information Literacy
COURSE MATERIALS REQUIRED
Safety Glasses, non-flammable clothing that covers the arms and legs, and hard-soled shoes.
TEXTBOOK, MANUALS, REFERENCES, AND OTHER READINGS
Chassis, 1/E, James D. Halderman, ISBN:9780558619305 and supplement, Publisher: Prentice
Hall Copyright: 2010. Note:
GENERAL INSTRUCTIONAL METHODS
Lecture, demonstration, videos, and PowerPoints,
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ASSESSMENT
Columbus State Community College is committed to assessment (measurement) of student
achievement of academic outcomes. This process addresses the issues of what you need to
learn in your program of study and if you are learning what you need to learn. The assessment
program at Columbus State has four specific and interrelated purposes: (1) to improve student
academic achievements; (2) to improve teaching strategies; (3) to document successes and
identify opportunities for program improvement; (4) to provide evidence for institutional
effectiveness. In class you are assessed and graded on your achievement of the outcomes for
this course. You may also be required to participate in broader assessment activities.
STANDARDS AND METHODS FOR EVALUATION
Students are required to demonstrate competency in a variety of tasks, read the assigned
textbook chapters, and take all quizzes and exams. Competency based evaluation is
accomplished by observing students performing evaluations and tasks.
• Periodic quizzes or a Midterm will be worth 30% of the final grade
• All lab work, including the assigned worksheets, other reports and class participation
will be worth 30% of the final grade.
• A number of individual hands-on evaluations. R/R drum brakes or measure and evaluate
an disc for machining are just two examples.
• A comprehensive final exam worth 20% of the final grade will be given at the end of the
quarter.
GRADING SCALE
The percentages earned will be added together to determine the final grade. The final grade will consist
of a letter grade which coincides with a range of percentage points earned as shown in the following
table:
92 to 100 % ............A
75 to 84 % ............ C
00 to 69 % ............ E
85 to 91 % ............ B
70 to 74 % ............ D
SPECIAL COURSE REQUIREMENTS None
ATTENDANCE POLICY
“Columbus State is required by federal law to verify the enrollment of students who participate
in Federal Title IV student aid programs and/or who receive educational benefits through the
Department of Veteran’s Affairs. It is the responsibility of the College to identify students who
do not commence attendance or who stop attendance in any course for which they are
registered and paid. Non-attendance is reported quarterly by each instructor, and results in
student being administratively withdrawn from the class section. Please contact the Financial
Aid Office for information regarding the impact of course withdrawals on financial aid
eligibility.”
There will be no make-up work (labs, quizzes or tests) given without prior approval from the
instructor. No makeup for lab assignments due to the nature of the assignment; therefore
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students should attempt to attend all lab sessions. Live lab assignments turned in one class day
late will be worth 80%, after that they will worth a zero. Written lab assignments turned in at
the start of class on the day they are due will be worth full credit, any assignments turned in
after the start of class on the day they are due will be worth 80% after that they will be worth a
zero. If a situation arises that prevents completing of this course, a grade of incomplete to be
requested. Arrangements for the incomplete must be made with the instructor prior to the end
of the quarter. Make-up assignments are at the discretion of the instructor and will usually be
in the form of a written assignment covering the topics of the questions in the missed quiz.
Make-up assignments will be limited to (2).
Illness Due to Influenza
Columbus State Community College is committed to maintaining a healthy campus community.
To help achieve this goal, we need student assistance in reducing the impact of both H1N1 and
seasonal flu viruses. Please review the following information.
When Should I Stay Home?
You should stay home if you are experiencing flu symptoms, as described in the Center for
Disease Control (CDC) website www.cdc.gov/flu or a fever greater than 100 degrees Fahrenheit
. The Columbus State website will post the CDC link as well as updates.
How Should I Report that I Am Staying Home With The Flu?
If you are staying out of class because you have flu symptoms, report your absence to your
instructor(s) as indicated on the course syllabus. Please note that if you have not reported your
flu-related absence, you will be subject to the assignment policy indicated in the syllabus.
What Are My Responsibilities?
• Report your absence due to flu symptoms to the instructor(s).
• Keep up with assignments and learning activities.
• Complete missed work upon return to class at the direction of the instructor(s).
• Keep a copy of your syllabus and other critical course materials, especially the contact
information for the instructor(s).
The college website will continue to provide updates. Direct links are www.flu.gov and
www.cdc.gov/flu
STUDENT CODE OF CONDUCT
As an enrolled student at Columbus State Community College, you have agreed to abide by the
Student Code of Conduct as outlined in the Student Handbook. You should familiarize yourself
with the student code. The Columbus State Community College expects you to exhibit high
standards of academic integrity, respect and responsibility. Any confirmed incidence of
misconduct, including plagiarism and other forms of cheating, will be treated seriously and in
accordance with College Policy and Procedure 7-10.
AMERICANS WITH DISABILITIES ACT (ADA) POLICY
2013-2014
It is Columbus State policy to provide reasonable accommodations to students with
documented disabilities. If you would like to request such accommodations because of
physical, mental or learning disability, please contact the Department of Disability Services, 101
Eibling Hall, 614.287.2570 (V/TTY). Delaware Campus students may also contact an advisor in
the Student Services Center, first floor Moeller Hall, 740.203.8000. Ask for Delaware Campus
advising, or www.cscc.edu/delaware, for assistance.
INCLEMENT WEATHER OR OTHER EMERGENCIES
In the event of severe weather or other emergencies that could force the college to close or to
cancel classes, such information will be broadcast on radio stations and television stations.
Students who reside in areas that fall under a Level III emergency should not attempt to drive
to the college even if the college remains open.
Assignments due on a day the college is closed will be due the next scheduled class period. If
an examination is scheduled for a day the campus is closed, the examination will be given on
the next class day. If a laboratory is scheduled on the day the campus is closed, it will be made
up at the next scheduled laboratory class.
Students who miss a class because of weather-related problems with the class is held as
scheduled are responsible for reading and other assignments as indicated in the syllabus. If an
examination is missed, contact me as soon as possible to determine how to make up the missed
exam. Remember! It is the student’s responsibility to keep up with reading and other
assignments when a scheduled class does not meet, whatever the reason.
In the event the college is forced to close during Final Examination Week, exams scheduled will
be rescheduled and students will be notified of the new time and date using their Columbus
State e-mail address and an announcement will be placed on Blackboard. Each student is
responsible for check their assigned email. Students lacking access to email at home must
prearrange with the instructor as to the alternate method of choice for being informed.
FINANCIAL AID ATTENDANCE REPORTING
Columbus State is required by federal law to verify the enrollment of students who participate
in Federal Title IV student aid programs and/or who receive educational benefits through the
Department of Veterans Affairs. It is the responsibility of the College to identify students who
do not commence attendance or who stop attendance in any course for which they are
registered and paid. Non-attendance is reported quarterly by each instructor, and results in a
student being administratively withdrawn from the class section. Please contact the Financial
Aid Office for information regarding the impact of course withdrawals on financial aid eligibility.
2013-2014
STUDENT LAB POLICIES AND PROCEDURES:
Student usage of facilities:
• Work performed in department lab will be for educational purposes ONLY. No individual is allowed to
gain financially on repairs performed in the shop.
• As part of coursework students may be allowed with instructor permission to work on their own personal
vehicles.
• No student or other non-automotive personnel is allowed in the shop unattended. All personnel working
in the shop are the responsibility of the instructor / lab technician who allowed them into the workshop,
no exceptions. Any one found to be working unattended will be required to remove the vehicle and
suspend work immediately and will not be allowed to return and / or complete work until properly
supervised.
• If a student desires out of class usage of the lab facilities, permission must be obtained from an instructor
and / or lab technician prior to the planned work. The instructor / lab technician granting the permission
will be expected to be present during the entire time the is work being done. (Consideration for staff /
faculty should be given before making requests for this type of work, because this will require their giving
up their own time to supervise your work).
Student usage of equipment and tools:
• The automotive department provides a lab outfitted with a wide variety of equipment that represents a
very substantial investment. This equipment is provided to allow all students the opportunity to use
equipment that they will work with in repair facilities after graduation. Students are expected to respect
the value of this equipment by using it responsibly.
• Students are not to use any piece of equipment that they have not been trained on in class without direct
guidance from an instructor / lab technician.
•
All tools checked out must be returned at the end of the class session.
• Departmental tools and equipment may not be used by students outside of the departmental lab areas.
This is due to the need for them to be available for other students for class work.
• The tools and equipment provided by the department must be accounted for and returned to their proper
place at the end of each class session. The instructor may assign two students per class session to clean
up the area used and return any tools and / or equipment used during the class. The facilities, equipment
and tools are benefits for the education of all students, be considerate of others.
• In the unfortunate circumstance that a student is found to be excessively misusing and / or abusing tools
and equipment the benefit of using them will be terminated.
Basic lab safety:
• Students are responsible for wearing appropriate clothing during lab exercises. Instructors will advise
students on appropriate clothing. Students repeated failure to wear appropriate clothing might result in
their being asked to leave the lab area until appropriately dressed.
• Approved eye protection MUST BE WORN at all times when in lab areas. A broad yellow line on the floor
and red signs posted in the areas designates these areas. This is mandated by Ohio law and must be
complied with, without fail. Students may obtain approved eyewear on their own or through the school.
Failure to wear approved eyewear will result in the student being removed from the lab area.
Any questions regarding these policies and procedures should be directed to the Department Chairperson, Andy
Rezin.
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AUTO 1150
Brakes Systems Theory and Operation
Unit
1
2
UNIT OF
INSTRUCTION
INTRODUCTION
PRECISION
MEASURING
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LEARNING OBJECTIVES/GOALS
Syllabus Presentation
Understand the course layout, topics to be covered and their
order, methods of evaluation, evaluation timeline, and the
instructor’s expectations.
Safety
Identify personal and property risks associated with brake
system service, such as:
•
•
•
•
•
Correctly use Micrometers
Brake Micrometers
Dial Indicators
Machinist’s Ruler
Torque Wrench
ASSESSMENT
METHODS
Questioning Quizzes
Observation
ASSIGNMENTS
Assigned
Reading
Quizzes
Lab Assignment
Assigned
Reading
3
BRAKE SYSTEM
OVERVIEW
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Brake System Tools Differentiate common hand tool from
brake system specialty tools
Brake System Configurations
Explain
• Disk VS Drum
• F/R VS Diagonal Split
Brake System Physics
Explain
• Kinetic Energy
• Heat Energy
• Levers
• Pascal’s Law
On-Car Inspection
Inspect
• Brake Fluid Condition
• Brake Fluid Level
• Power Booster Operation
• Warning Light Operation
• Pedal Height
• Pedal Reserve
On Car Measurements
Measure
• Brake Rotor Runout
• Brake Rotor Parallelism
• Brake Drum Runout
• Brake Lining Thickness
• Miles until replacement
Quizzes
Lab Assignments
Quizzes
Assigned
Reading
4
DRUM BRAKES
Explain
• Advantages of Drum Brakes
• Disadvantages of Drum Brakes
Types of Drum Assembly
Identify various types of drum brake assemblies
Parts
Identify the parts of a drum brake assembly
Explain how the parts work and connect.
Adjust Lining clearance and parking brake
Wheel Cylinder Inspection
Inspect Wheel cylinders for proper operation
Brake Shoes
Explain shoe construction
Explain lining types and materials
Inspect Linings for normal/abnormal wear and proper fit.
Adjust brake shoes and parking brake assemblies.
Drums
Explain and Identify types for brake drums
Inspect Drums for wear and distortion
Recommend proper service procedures for different types or
drum wear
Demonstrate proper procedures for dust removal and remove
a brake drum.
Removal and Installation
Remove and reinstall a brake drums, shoes, and springs using
proper procedures
Drum Brake Individual Assessment Each student will R/R the
following types of drum brakes:
• Duo-Servo
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Observation
Questioning
Quiz
Written Lab Sheets
Assigned
Reading
Review the
function and
location of
drum brake
parts
• Leading Trailing
Each student will measure a brake drum and make a
recommendation regarding its serviceability
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5
DISC BRAKES
Explain the advantages and disadvantages
Types of Calipers
Identify and classify the type of caliper presented
Caliper Service
Explain proper functioning and lubricate parts with the correct
lubricant.
Brake Pads
Identify and classify various types of brake pads
Rotors
Identify and classify various types of brake rotors
Rear Disc Brakes
Use Show-and-tell parts as well as Overhead graphics and
explain how each part works
Demonstrate Piston retraction
Servicing
Evaluate rotors pads and make recommendations
Disc Brake Assessment
Each student will measure a disc and make a recommendation
regarding its serviceability
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Observation
Questioning
Quiz
Written Lab Sheets
Assigned
Reading
6
HYDRAULICS
Brake Line Types
Explain brake line construction
Explain brake line fabrication
Explain brake line fittings
Inspect brake line and report condition
Brake Line Configurations
Identify various brake line configurations.
Note that four channel ABS may look like diagonal split.
Brake Fluid
Explain The difference between various types of brake fluids
and when each type would be used.
Explain the use for the SAE number on the can
Explain precaution necessary when handling brake fluid
Master cylinder
Explain:
• Low pressure chamber
• High pressure chamber
• Inlet or replenishing port
• Compensating port
• Internal vs. external leaks
Demonstrate R/R and bench bleeding
Hydraulic Control Valves
Explain how and when the valves operate.
Explain how and why the metering valve can be disabled
Wheel Cylinders
Explain how wheel cylinders are removed, overhauled and
installed
Demonstrate removal and reinstallation
Calipers
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Observation
Questioning
Quiz
Written Lab Sheets
Assigned
Reading
Explain how calipers are removed, overhauled and installed
Demonstrate disassembly and reassembly
Bleeding the System of Air
Explain and Demonstrate various methods of bleeding brake
system.
Explain when bleeding the system is necessary
Bleed the brake system
Brake Line Fabrication
Properly flare a brake line and then bend it into an “S” shape
without collapsing the tubing
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7
POWER AND PARKING
BRAKES
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Power Assist
Identify and explain the difference in various type of boosters
(servos)
Performance Testing
Explain and demonstrate the procedure.
Booster Removal
Explain the procedure
Parking Brake Testing
Explain the procedure and evaluate operation
Cable Removal
Explain the procedure
Observation
Questioning
Quiz
Written Lab Sheets