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BRAKES
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12.MAINTENANCE, INSPECTION AND TEST
DO’S
Do inspect fluid level regularly and top up if
necessary
Do exercise scrupulous cleanliness when
dealing with hydraulic system.
Do use only fresh brake fluid or alcohol for
cleaning internal parts of the hydraulic system.
Do use only genuine kits for servicing the
cylinders.
Do use only genuine DOT-4 brake fluid.
Do fill the oil till max level whenever the system
is flushed completely then while bleeding.
Do use fluid from sealed container.
DON’TS
Do not allow the brake fluid to come below min
level in reservoir.
Do not use kerosene / petrol / diesel for
cleaning the cylinders.
Do not use the cylinders if the bore is scored or
corroded.
6.1.2.1 PRELIMINARY INSPECTION
For a system as important as Brakes, it should be
doubly ensured that it is in good condition
throughout. The only way to do so is to inspect the
brakes every time the vehicle visits the workshop.
A. FRONT BRAKE AND REAR BRAKE
Check the pads for wear, if excessive wear is
observed or suspected, remove them from the
caliper assembly inspect them as per the
procedure given in ‘Caliper Pad Replacement’.
Check the disc for any scores, grooves or any
uneven wear, if found follow the instructions in
the section ‘Front Brake Disc Removal’.
Wipe the disc with a clean dry cloth.
Ensure no oil or grease traces on brake discs
and on brake pads.
B. PARKING BRAKE
Pull the parking brake and count the notches
engaged, the travel should not be more than 3-
4 notches, if it is more follow the instructions in
the section ‘Parking Brake Adjustment’.
C. BRAKE HOSES AND LINES
Any traces or evidences of brake fluid leakage
should be inspected and the cause found and
rectified immediately.
All brake hoses and line should be replaced
once every 1, 50, 000 Kms or 3 years
whichever is earlier.
The brake hoses should be checked for any
pinching, damage, cracks, leakage etc. Proper
routing, clamping and mounting of hoses and
lines should be ensured.
Vacuum circuit (Pipelines, hoses etc.) to be
checked. Proper routing & clamping of lines to
be ensured.
D. ROAD TEST
NOTE
Before starting the road test ensure proper inflation
of tires as per specification.
Road test for the brakes should be taken by a
skilled driver with sufficient experience.
Brakes shall be tested on dry, clean smooth
and reasonably level road which is not
crowded.
Drive the vehicle at low speeds in a safe area.
Test the brakes by making brake applications
with both light and heavy pedal forces at
various speeds to determine if the vehicle stops
evenly and effectively.
Test carried out after wheel balancing and wheel
alignment will give a better clarity and help in
better, specific identification of a brake related
defect.