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Brake System Maintenance Checklist
Introduction
The Brake System Maintenance Checklist is a comprehensive tool designed to ensure the safety and reliability of commercial vehicle braking systems. Proper brake maintenance is not only critical for safety but also a legal requirement under DOT regulations. This detailed checklist covers all essential components of air brake systems, hydraulic brakes, and related subsystems to help mechanics and maintenance personnel conduct thorough inspections, identify potential issues, and document maintenance activities.
Regular use of this checklist helps prevent brake failures, reduces roadside breakdowns, ensures compliance with FMCSA regulations, extends component life, and creates a documented maintenance history. Whether performed during preventive maintenance intervals, during repairs, or as part of a safety program, systematic brake system inspection and maintenance is one of the most important activities in keeping a commercial fleet safe and compliant.
Vehicle & Service Information
Pro Tips for Brake System Maintenance
- Listen During Test Operations: Auditory inspection is just as important as visual. When performing operational tests, listen for air leaks, unusual sounds during application, or mechanical noises that might indicate wear or impending failure. Different sounds can help pinpoint specific issues in the brake system.
- Check Temperature Patterns: After a road test, use an infrared thermometer to check brake component temperatures. Uneven temperatures across wheels can indicate dragging brakes, inoperative components, or adjustment issues. All brakes should show similar temperature patterns after similar use.
- Document Component Measurements: When checking brake components, record actual measurements (brake pad thickness, rotor/drum dimensions, pushrod travel) rather than just "pass/fail." This creates a history that helps predict wear rates and plan for future maintenance.
- Verify System Timing: The timing of air brake application and release is critical for safe operation. Measure and record the time for pressure builds, application, and release to ensure they meet manufacturer specifications. Timing issues can indicate internal valve problems or restrictions.
Air Brake System Components
Brake Chambers & Components
Slack Adjusters & Linkage
Brake Drums & Rotors
Brake Linings & Pads
Air Control Valves
Hydraulic Brake Components
Anti-Lock Brake System
Parking Brake System
Operational Tests
Brake System Inspection Procedures
Follow these detailed procedures to ensure a thorough and systematic brake system inspection that complies with industry standards and identifies potential issues before they lead to failures.
Air Brake System Test Protocol
- Start with system fully charged (120-135 psi)
- Perform governor cut-out/cut-in test (record pressures)
- Conduct static leak test with brakes released (< 2 psi/min)
- Perform applied leak test with brakes applied (< 3 psi/min)
- Test low air warning device activation (55-60 psi)
- Check spring brake activation (20-40 psi)
- Verify pressure build time (50-90 psi within 3 min)
- Test tractor protection valve at 20-45 psi
Brake Adjustment Measurement
- Ensure vehicle is on level surface with wheels chocked
- Release all brakes and ensure system is fully charged
- Mark pushrod at brake chamber face at released position
- Apply full service brake application (90+ psi)
- Measure pushrod travel from mark to chamber face
- Compare to maximum allowable stroke for chamber type
- Record measurements for all wheels
- Adjust brakes that exceed 80% of maximum stroke
Brake Component Inspection
- Remove wheels if necessary for full inspection
- Measure drum diameter or rotor thickness with proper tools
- Measure brake lining/pad thickness at thinnest point
- Inspect friction material for cracks, contamination
- Check return springs for proper tension
- Inspect cam bushings and rollers for wear
- Verify all hardware is present and secure
- Document all measurements for maintenance records
Hydraulic System Check
- Inspect fluid level and condition in master cylinder
- Check for evidence of fluid leaks under vehicle
- Test pedal firmness and travel distance
- Inspect all brake lines and hoses for damage
- Verify wheel cylinders/calipers for leaks or binding
- Test hydraulic boost system (vacuum or hydraulic)
- Check warning light operation for low fluid/pressure
- Perform functional test of all brakes
Inspection Progress
0% complete
Technician Certification
I certify that I have inspected the brake system components as documented above according to industry standards and applicable regulations, and that all findings are accurate and complete.
Supervisor Verification
I have reviewed this brake system inspection and verify that it has been performed according to company procedures and applicable regulations.
Service Notes & Measurements
Regulatory Standards & Requirements
Understanding the regulatory requirements and industry standards for brake systems is essential for maintaining compliance and ensuring safety. This section outlines key requirements that must be met during brake system maintenance.
FMCSA Brake Requirements
- Vehicle must have operable service brakes on all wheels
- Brake linings/pads must be at least 1/4" thick (1/16" for disc pads)
- No cracks in drums/rotors that extend to cooling vents
- No oil/grease contamination on friction surfaces
- No audible air leaks in brake chamber/lines
- Air system must build to 85-100 psi within 45 seconds
- Low air warning device must function at 55-60 psi
- Parking brake must hold vehicle on 20% grade
Brake Adjustment Limits
- Type 6 brake chambers: 1 1/4" maximum stroke
- Type 12 brake chambers: 1 3/8" maximum stroke
- Type 16 brake chambers: 1 3/4" maximum stroke
- Type 20 brake chambers: 1 3/4" maximum stroke
- Type 24 brake chambers: 1 3/4" maximum stroke
- Type 30 brake chambers: 2" maximum stroke
- Long stroke chambers have different specifications
- 20% of brakes out of adjustment is an OOS condition
Out-of-Service Criteria
- 20% or more brakes defective or out of adjustment
- Any single brake with inoperative parts
- Missing or broken mechanical components
- Audible air leak at brake chamber
- Brake linings/pads contaminated with oil/grease
- Brake adjustment beyond maximum adjustment limits
- Missing or defective ABS when required
- Inoperative or defective required brake components
Documentation Requirements
- Record specific measurements of components
- Document all parts replaced during service
- Note brake adjustment measurements before/after service
- Document air system test results with specific pressures
- Record ABS diagnostic results if performed
- Note conditions requiring future attention
- Maintain records for minimum of 12 months
- Include technician certification information
Conclusion
Implementing this comprehensive Brake System Maintenance Checklist as part of your routine fleet maintenance program is essential for ensuring vehicle safety, regulatory compliance, and optimal brake system performance. By systematically inspecting and documenting all brake components and functions, maintenance personnel can identify potential issues before they lead to failures, extend component life through proper adjustment and service, and maintain a complete service history for each vehicle.
For optimal brake system maintenance management, consider implementing the FleetRabbit software to streamline your inspection and service documentation process. The FleetRabbit platform allows digital documentation of all brake measurements and inspections, provides automatic alerts for components approaching wear limits, and creates comprehensive maintenance histories for each vehicle. With the FleetRabbit APP, maintenance managers can easily track brake component wear trends, schedule preventative maintenance based on actual condition data, and maintain thorough documentation for regulatory compliance.
Make brake system maintenance a priority in your fleet operations with the FleetRabbit software's comprehensive maintenance management solution. Whether for regulatory compliance, safety assurance, or optimal vehicle performance, this digital approach significantly improves maintenance thoroughness and documentation while reducing administrative burden on technicians and maintenance personnel.
Access the digital version of this checklist through the FleetRabbit APP
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