Assembling braking systems to vehicles
Overview
This standard identifies the competences you need to assemble braking systems to vehicles, in accordance with approved procedures. You will be required to assemble a range of different braking systems and associated components to the vehicle, by using a variety of assembly methods and techniques. You will also be expected to use a range of tools and specialist equipment associated with the assembly methods, checking that the assembly has been completed to the level of accuracy and quality required by the specification.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the process that you cannot resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying vehicle braking systems assembly procedures. You will understand the assembly methods and techniques used, and their application, and will know about the tooling and ancillary equipment, braking system components and consumables, to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions to be followed when carrying out the assembly activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
- assemble the components in their correct positions, using appropriate methods and techniques
- secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and activities and the responsibility they place on you
- the hazards associated with the activities, and how to minimise them and reduce any risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the procedures for obtaining the various types of drawing, job instructions and specifications that are used during the assembly of braking systems to vehicles, and how to interpret them correctly
- how to identify the components to be used; component identification systems (codes and component orientation indicators)
- the assembly methods and procedures to be used, and the importance of adhering to these procedures
- how the components are to be aligned and positioned, prior to securing and the tools and equipment that are used (including jigs and fixtures)
- the various mechanical fasteners and other components that are used (threaded fasteners, set and self-tap screws, spring clips and other specialised fasteners)
- the application of sealants and adhesives within the assembly activities, and the precautions that must be taken when working with them
- the operational function of the various braking systems that are used
- the use of torque wrenches and the importance of ensuring fasteners are adjusted to the required settings
- how to charge the braking systems with fluid and carry out the brake bleeding activities (to include the use of brake bleeding/setting equipment)
- how to set and adjust mechanical brakes, and the equipment that is used for this
- the consumables, tools and equipment that are used for assembly of the braking systems to the vehicle
- the importance of using the specified fasteners for the assembly and why you must not use substitutes
- how to deal with components or fastening devices that are incorrectly assembled, damaged or have other faults
- the quality control procedures to be followed during the assembly operations
- how to conduct any necessary checks to ensure the accuracy and quality of the assembly produced
- how to recognise defects (incorrect assembly, ineffective fasteners, component damage)
- the importance of ensuring that the completed assembly is free from left-over items and foreign objects
- the methods and equipment used to transport, handle and lift the components into position, and how to check that the equipment is within its current certification dates
- the preparations to be undertaken on the components and fixing points, prior to fitting the assembly into the vehicle (including ensuring that exposed component openings and pipe ends are free from dirt and foreign bodies)
- the importance of ensuring that brake fluids do not come into contact with brake linings/pads and any part of the vehicle paintwork
- how to check that the tools and equipment to be used are correctly calibrated and are in a safe, tested and serviceable condition
- the importance of ensuring that all tools are used correctly and within their permitted operating range
- problems with the assembly operations, and the importance of informing appropriate people of non-conformances
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the assembly activities:
- obtain and use the appropriate documentation (such as job instructions, assembly drawings, quality control documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- check that all cables, extension leads or air supply hoses are in a safe, tested and serviceable condition
- check that all tools and equipment to be used are within current calibration/certification dates
- ensure that sub-assemblies and components used are free from damage, foreign objects, dirt or other contamination before assembling them
- use lifting and slinging equipment in accordance with health and safety guidelines and procedures
- use safe and approved techniques to assemble the sub-assemblies and components to the vehicles
- return all tools and equipment to the correct location on completion of the assembly activities
- leave the work area in a safe and appropriate condition on completion of the activities
Assemble complete braking systems to the vehicle, to include two of the following:
- disc brakes
- drum brakes
- mechanical/hand brakes
- anti-lock braking systems (ABS)
Assemble braking systems, to include three of the following:
- bolts
- rivets
- set screws
- adhesives
- other specific securing devices
Assemble components using three of the following devices:
- power drivers
- fluid filling devices
- compression/expansion devices
- torque drivers
- measuring devices
- lifting devices
- pipe fittings/connectors
- clip/spring fastenings
Assemble components to the vehicle, using two of the following setting devices:
- computerised brake sensing/setting devices
- brake bleeding devices
- other specific brake assembly devices
Assemble vehicle braking systems, to include fitting eight of the following components:
- master cylinder
- sensors
- hoses and pipes
- wheel cylinders
- brake pads
- servo units
- brake cables and links
- callipers
- pressure equalising units
- handbrake mechanisms
- brake discs
- other specific components
Check assemblies comply with all of the following quality and accuracy standards:
- all pipework and cabling is correctly positioned to avoid damage
- pipe joints are free from leaks
- all connections are made to the correct torque loading
- brake mechanisms are correctly adjusted
- the system is free from air and contaminants and complies to specifications