1. Orientation to Hydraulic Brake Systems. Module One Chapter 4

2. Copy of objective sheet Copy of key terms Copy of ASE style review questions Copy of task sheet and PPE Notebook Pen/Pencil Materials

3. For students to understand the basic theory of operation, components and maintenance of today's hydraulic brake systems. Goals

5. Describe the operation of drum brakes, disc brakes and dual brakes in a hydraulic braking system.

6. Describe the operation and maintenance of : Wheel Cylinders, Calipers, Master Cylinder, Combination Valve. Objective

7. Hydraulics A Hydraulic Brake System is a system utilizing the properties of fluids under pressure to activate the brakes to create friction to stop a moving vehicle. Typical hydraulic brake systems use DOT 3 or 4 fluid but some systems use silicone based DOT 5 fluid. Be careful “not” to mix Dot3/4 with DOT5. Avoid spilling brake fluid on the paint . Brake fluid will fade or remove the paint!

8. As you depress the brake peddle you transmit the energy from your leg onto the brake peddle lever. This force is multiplied by the length and lever position of the peddle to the master cylinder. System operation

9. The movement of the brake peddle creates flow from the master cylinder through the combination valve and into the larger brake actuators again, multiplying the braking force. System Operation

10. Master Cylinder Most vehicles today use master cylinders that have the reservoir built onto the master cylinder with two sumps to store the brake fluid. They are duel system type master cylinders that create flow to the larger diameter slave cylinders like your wheel cylinders and caliper assemblies.

12. Metering (front brakes)

13. Proportioning (rear brakes) Combination Valve

14. Brake systems must be able distribute braking force to the wheels as evenly as possible to prevent wheel lock up, nose diving, brake fade. To do so they use the combination valve. Combination Valve

15. After pressurized fluid is moved from the master cylinder through the combination valve it is carried to the actuator through the use of steel or rubber brake lines. Brake Lines Never attempt to repair brake lines!

16. The wheel cylinder converts the hydraulic energy into mechanical energy to actuate the brake shoes. Wheel/ Slave Cylinder

17. The wheel caliper is the actuator for disc brake systems. It is highly efficient and provides substantial leverage in the squeezing action of the brake pad against the brake rotor. Wheel Caliper

18. The brake pads and shoes are the heart of the system. These components provide the stopping friction needed to apply the brakes. The material they consist of varies from organic to man made fibers. Some contain asbestos so, proper PPE is a must when performing maintenance. Brake pads and shoes

19. The Brake drum and Rotor are the final component in the Hydraulic Disc and Drum brake system. They are made of hardened steel and designed to absorb the heat produced by the friction needed to stop the vehicle. Brake Drum and Rotor

20. There is little maintenance involved in the hydraulic brake system outside of periodic cleaning, inspection and adjustment of brake pads and shoes. If the master cylinder is replaced peddle free play needs to adjusted. The brake fluid should be inspected periodically as well and changed if discoloration or high moisture content is evident. Maintenance High Pressure oil, airborne partials and stored energy from springs will get you! Wear your PPE!

21. Who knows what the definition of Hydraulics is? Name the components in order that make up a basic hydraulic brake system. (Be as detailed as possible “one component per student”). Why should you not mix DOT3 and DOT 5 brake fluid? How is braking force multiplied? What type of maintenance do you need to perform on Hydraulic brake systems? What safety areas do you need to be aware of when working on or around brake systems? Review

22. www.howstuffworks.com www.2CarPros.com Next Lesson: Troubleshooting, Parts replacement and adjustment of Hydraulic Brake Systems. Additional Information can be found at: