Brakes

Question: How does a brake system inspection work?

Answer: Brake system inspection is an absolute must to ensure safe driving conditions.
During a brake inspection the entire brake system is checked; this includes the following:
the brake pedal, brake fluid, brake lines and hoses, and the brake assemblies (whether
they are disc brakes or drum brakes). Parking brakes should also be checked at this time.
Checking how your brake system is working starts with your brake pedal. There are three
things to check when it comes to your brake pedal. The brake pedal’s height should be
checked along with measuring free play and the brake pedal reserve distance. All of these
measurements should be compared with the vehicle manufacturer’s specifications. The
brake pedal height is the measurement of the brake pedal to the floor when the brake
pedal is at rest. Free play means that when you step on the pedal the brakes aren’t
applied right away. The free play is measured by the pedal movement from rest until the
brakes are actually applied. Pedal free play is actually required, but it is important the free
play measurement is in accordance with the specifications of the manufacturer. Lastly is
brake pedal reserve distance. This is the distance from the pedal to the floor when the
brakes are applied. So, if your pedal’s height is off or if there is excessive free play, there
may be problems with your pedal bushings and return springs. If the reserve distance is
incorrect, there may be problems with the cylinder pushrod.

Next, your brake fluid should be checked. Brake fluid provides the necessary force to
activate your brake shoes and compress the brake pads or brake shoes. Brake fluid is
kept in the master cylinder and experts say it should be changed every year or two to
ensure your brakes will work properly. Along with checking the brake fluid, the hoses and
lines should be checked. If the master cylinder is low, there may be a leak somewhere in
the lines. The lines and hoses can be visually checked for cracks, and the actual brake
assembly can be checked for moisture. You can also place cardboard under your vehicle
and step on your brakes several times. Then check the cardboard for any leaks.

Finally, the brake assemblies are checked. To inspect the brakes, your front and rear
wheels are removed to get a better view of the brake assemblies. There are two different
types of brake assemblies: disc brakes and drum brakes. Let’s discuss inspecting disc
brakes first. There are three things that must be inspected on disc brakes: the brake pads,
brake rotor, and the caliper. The brake pads are located on each side of the rotor and are
actually pushed against the rotor to stop the wheel and stop your vehicle. The pads create
the necessary friction to stop the vehicle. The pads are checked for excessive wear to
make sure there isn’t metal rubbing on metal. The brake rotor is the iron disc that is
connected to the tire’s hub. Rotors must be inspected for excessive wear. Brake pads and
rotors have matching wear patterns, and if a brake pad needs to be replaced, the rotor will
have to be machined smooth. A rotor can be machined smooth only so many times before
it is worn too much. Each rotor must have a certain width, which is inscribed on the rotor,
and if the rotor is too worn, it must be replaced. The rotor should also be inspected for any
heat cracks or other damage. The last part of a disc brake is the caliper. The caliper is a
device located over the top of the rotor and contains both brake pads. There are two types
of calipers: floating calipers and fixed calipers. A floating caliper can compress itself and
contains only one piston. When the brakes are applied, brake fluid will force the piston into
the brake pad, which will press against the rotor. Then the other side of the caliper will
press the other brake pad against the rotor to stop the wheel and vehicle. A fixed caliper
doesn’t move; so, it contains two pistons located on each side of the rotor. When the
brakes are applied, brake fluid forces both pistons into each brake pad which press
against each side of the rotor to stop the wheel and vehicle. Calipers must be inspected to
check for leaks.

The second type of brake assembly is the drum brake. Drum brakes are usually located
on rear wheels because of the need for a parking brake. Parking brakes are added much
easier to a drum brake than to a disc brake. Drum brakes contain several different parts:
brake shoes, which are like brake pads; a backing plate, which basically holds everything
together and is attached to the axle; brake drum, which is like the brake rotor; wheel or
brake cylinder, which contains the pistons; return springs; and a self-adjusting system that
will adjust the position of the brake pad when the brake isn’t applied. When the brakes are
applied, brake fluid forces the pistons to push against the brake shoes, which press
against the drum, which will stop the wheel and vehicle. Then, when the brake is released,
the return springs send the brake shoes back to their original position. Brake shoes are
located very close to the drum so that when you step on your brake pedal, the brakes are
immediately applied. Over time, the surface of the brake shoes wears and the position of
the shoes must be adjusted so it doesn’t have to travel a farther distance to come into
contact with the drum. If the drum brakes didn’t have a self-adjusting system, you would
have to press down farther and harder on your brake pedal before the brakes would be
applied. When a drum brake is inspected, there are many more parts that need to be
checked than in a disc brake. The brake shoes need to be checked for excessive wear so
they don’t damage the drum. The brake drums, like the rotor, need to be checked for
excessive wear or cracks. They also have to be machined smooth when a brake shoe is
replaced and can only be machined down so far; then they must be replaced. Wheel or
brake cylinders need to be inspected for any signs of leaking. The return springs need to
be checked because if they are too worn and don’t return the brake shoes back to their
original position, away from the drum, the brake shoes can experience rapid and
excessive wear.

Finally, the self-adjusting system must be inspected to make sure it is clean and properly
lubricated. Parking brakes should also be inspected at this time. A parking brake, or
emergency brake, must be inspected to make sure that the cables and levers are working
properly. Parking brakes work separately from your regular hydraulic brakes. They are a
necessity to keep your vehicle from rolling down a hill when it is parked. It must also be
working properly if your regular hydraulic brakes ever fail.

So how do brake testers work?

The brake tester’s mechanism safely measures the maximum braking force of a vehicle
while the vehicle is stationary. It consists of an automated weighing system that accurately
calculates the braking efficiency of the vehicle.

The brake tester consists of weighing cells on each side of the unit with a safety roller that
detects whether a vehicle is present in the tester - this will also monitor any tyre slippage.

The vehicle is driven onto the brake tester with its wheels centrally located between the
two larger main rollers. The brake tester is designed with a gritted surface to ensure
maximum tyre protection and to simulate a common road surface. Once the vehicle
details have been entered the rollers are then automatically switched on and rotate at a
designated and consistent speed. The vehicle’s brakes are then applied by the operator,
thus creating a force on the motor. A transducer measures the braking force of each
wheel as the vehicle decelerates. During the process fluctuation is also measured to
determine the safe balance of braking force between near and off side wheels calculating
the difference in percentage form.

Our testers are easy and efficient to use. The user can operate the brake tester whilst
sitting inside the vehicle by a user-friendly remote control via Crypton’s control station
(combined emissions analyser). Due to the smooth and automatic running of each roller,
the operator can also feel for any grab or binding that occurs whilst sitting in the vehicle
during the test.

Crypton, a brand of Continental is one of the most recognised suppliers to the automotive
trade. We supply automated brake testers and HGV brake testers as part of our garage
equipment range.