504 BRAKE SYSTEM 6.3 MAINTENANCE, ADJUSTMENTS AND INSPECTIONS To maintain the efficiency of the brake system following preventive maintenance is essential. (a) Always use genuine grade of service replacement lined shoes. (b) Do not contaminate the brake lining surface with oil or grease. (c) The brake shoes have to be replaced in sets only. If you are replacing brake shoes on left side then the brake shoes on right side should also be replaced. After replacement of new brake lining, - Set the brake shoe dia. to 179.5 mm. - Assemble the drum - In vehicle static condition, press brake pedal 30 - 40 times and ensure the pedal travel is in acceptable condition. (d) Increased foot pedal travel and hand brake lever movement is an indication that automatic adjustment mechanism has reached its stop limit. 1. MAINTENANCE OR SERVICE LIMITS : 1.1 Friction Material (Front and Rear) Do not allow the friction material or brake liner to wear below 1 mm from brake shoe-rim surface. (Brake liner thickness is 4.2 to 4.8 mm) For brakes with make Bosch Front (mm) Rear (mm) Brake Rim Thickness 2 1.6 Liner Thickness 4.2 4.2 For brakes with make Brakes India Ltd. (BIL) Front (mm) Rear (mm) Brake Rim Thickness 1.6 1.6 Liner Thickness 4.8 4.8 1.2 Tandem Master Cylinder If, the clearance between the piston and cylinder bore exceeds 0.20mm, TMC assembly should be replaced. 1.3 Wheel Cylinder If, the clearance between the wheel cylinder piston and cylinder bore exceeds 0.20 mm, Wheel cylinder assembly should be replaced. 1.4 Seals As per the preventive maintenance schedule, all rubber parts (including seals) should be replaced after 40,000 kms or two year, whichever occurs earlier. 1.5 Brake Fluid As per the preventive maintenance schedule, brake fluid should be flushed and replaced after each 40,000 kms or two year, whichever occurs earlier.
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