504 / 896
512
BRAKE SYSTEM
TROUBLESHOOTING CHART FOR BRAKE SYSTEM IS AS GIVEN BELOW:
TROUBLESHOOTING OF BRAKE SYSTEM
CONCERN
CAUSE
REMEDY
Not enough braking effect
1. Brake oil leakage from brake lines 1. Find out the leaking area and repair.
2. Poor contact of shoes with brake 2. Repair for proper contact
drum
3. Brake shoe linings stained with 3. Replace brake shoes
oil or wet with water
4. Defective wheel cylinders
4. Repair or replace
5. Air in system
5. Bleed system
6. Badly worn brake shoe linings
6. Replace worn shoes.
Brake pedal pulsation
1. Damaged or loose wheel bearings 1. Replace wheel bearings
(pedal pulsates when
2. Distorted steering knuckle
2. Replace steering knuckle
depressed for braking)
3. Brake drums are out of round
3. Repair or replace as necessary
High Brake pedal travel
1. Excessive clearance between
1. Adjust brakes
(pedal may go to floor)
drums and linings
2. Automatic adjusters not working 2. Make several forward and reverse
brake stops; if pedal does not come
up, repair automatic adjusters.
3. Bent or distorted brake shoes.
3. Replace shoes and linings in sets,
Leak in hydraulic system.
Check master cylinder, wheel
cylinders, tubes, and hoses for
leakage; repair or replace faulty
parts.
4. Air in hydraulic system.
4. Bleed hydraulic system.
5. Poor quality brake fluid ( Low 5. Drain hydraulic system and fill with
boiling point )
approved brake fluid
6. Low brake fluid level
6. Fill master cylinder and bleed
hydraulic system.
7. Weak brake hoses that expand 7. Replace defective hoses.
under pressure
8. Residual pressure check valves 8. Repair or replace master cylinder.
not holding pressure in lines.
Spongy brake pedal
1. Air in hydraulic system
1. Bleed the system and top up brake
oil.
2. Soft or weak brake hose that
2. Check and replace hose.
expands under pressure
3. Poor quality brake fluid
3. Flush the system and refill with
recommended grade of brake fluid.
4. Excessive worn/weak drums
4. Replace drums
Brake rough or chatter on 1. Excessive run out in drum
1. Repair if possible or replace the
application
drum if not within specifications
2. Incorrect parking brake adjustment 2. Check and adjust as per
specifications
3. Damaged or loose wheel bearing 3. Replace wheel bearing
4. Distorted steering knuckle or
4. Replace knuckle or drive shaft.
drive shaft