3.2 Brake Systems

Information Method of Inspection Reason for rejection
Some braking systems have levers which are designed to operate over-centre

Check for any movement at the bolts securing the back plate reaction brackets or calipers by rocking the machine backwards and forward with the brake applied.

Where there is doubt about the effect of an observed defect, the tester may at his discretion carry out a road test. (See Introduction item 10)

Fully floating brake discs are designed to havesome movement. Care must be taken to not unnecessarily fail these items for security.

It may be necessary to use an assistant to operate the brake/s to ascertain the condition and adjustment of the mechanical components.
A. MECHANICAL BRAKE COMPONENTS

1. Examine all the mechanical components of the brakes which can be seen without dismantling, looking particularly for:

a. badly chafed rods or levers

b. corroded, frayed or knotted cables, or crushed outer casings

c. corroded or damaged rods, levers or linkages

d. worn clevis joints e. absence or insecurity of locking devices

f. the thickness of brake linings or pads

g. insecurity or cracking of brake drums or discs

h. any restriction to the free movement of the mechanism

i. abnormal movement of levers indicating maladjustment or excessive wear

j. insecurity of brake back plates, reaction brackets or calipers;

k. contamination of friction surfaces by oil or grease

l. brake disc scoring, pitting or wear;

m. brake disc run-out.
1. Serious reduction in strength of any component due to excessive wear, cracking or damage (eg a brake rod reduced in diameter by more than 1/3rd of original dimension)

a. excessive chafing to rods or levers

b. a knotted, excessively corroded or badly frayed cable or a significantly damaged outer casing

c. excessive corrosion or damage to rods, levers or linkages

d. an excessively worn clevis joint

e. the absence or insecurity of locking devices (eg lock nuts, split pins etc)

f.
(i) Brake linings or pads, (other than sintered pads) less than 1.5mm thick at any point
(ii) Sintered brake pads less than 1.0mm thick at any point

g. An insecure or cracked brake drum or disc or securing bolts loose or missing

h. any restriction to the free movement of the system likely to impede its operation

i. abnormal movement of levers indicating maladjustment or excessive wear. (see information column)

j. an insecure brake back plate, reaction bracket or caliper. Securing bolts loose or missing. (see information column)

k. contamination of friction surfaces by oil or grease

l. an excessively scored, excessively pitted or excessively worn brake disc

m. excessive run out or distortion of a brake disc.
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