BRAKES 20 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 34 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.
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