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Disc Brake Maintenance

When you put your foot on the brake, are you confident that the machine you are operating will stop? Keeping brakes in good working condition is essential for safe machine operation. The only way to ensure that your brakes will be there when you need them is to follow a thorough maintenance program. 

Construction and mining equipment use a variety of brake system types – drum, dry disc, wet disc and hydrostatic. Dry disc brakes are popular on a wide range of machines including front-end loaders, articulated haulers, and rigid frame haulers. Although similar to the type found on most automobiles, these disc brakes are considerably larger. 

A disc brake consists of a disc, or rotor, which rotates with the wheel, and a stationary caliper which holds the brake pads or “linings.” Hydraulically actuated pistons press the linings against the disc. This causes friction and heat energy which stops the disc and machine.
 
Disc brake enemies include dirt, heat and water in the air or hydraulic system. Spend a few minutes checking the brakes at each wheel, and you’ll save considerable money and downtime if the brakes need to be overhauled or the disc replaced. 

Performing a weekly or monthly brake system inspection is a simple, cost-effective way to avoid larger, more expensive problems in the future. Also, since you rely on brakes in an emergency, the few minutes spent at each wheel may prevent injury and machine damage. 

Depending on machine type, visually inspecting the brake(s) and disc is usually fairly easy. Check the linings for severe or abnormal wear. A taper or worn spot in one area means the brakes have been severely used (many frequent high-speed stops) or abused (operator riding the brakes) and the lining should be replaced. 

At the end of a shift, if a walk around inspection reveals one or two discs are cooler than the other disc, investigate to find out if all brakes are operating properly. Measure discs with deep grooves or wear marks to make sure they have not worn past the manufacturer’s specified minimum thickness. If material is available, the discs can be turned. This is usually less expensive than buying new. 

If the disc is too thin and the linings worn, the linings could fall out, resulting in complete loss of brake power. Cracking or discoloration of the disc means the brakes have seen excessive heat. This could be due to a faulty component in the air or hydraulic system, or the operator may be riding the brake pedal. 

Wash dirt, sand, and mud from around the disc and brake to prevent linings and discs from wearing abnormally fast. Wash more frequently in harsher environments. Look for wet oil on the brake or wheel possibly indicating a loose-fitting bleeder or hose problem. 

Finally, do not forget the hardware. Tighten loose and replace missing nuts and bolts.