Common Faults and Treatment Methods of Industrial Disc-Type Hydraulic Brakes

I. Brake failure or insufficient braking force

Fault phenomenon:

• There is no obvious braking force when braking.
• It takes multiple times to generate braking force.

Treatment method:

1. Check if the hydraulic oil level is too low and replenish the special brake fluid in time.
2. Check for any leakage in the brake lines and tighten the joints or replace the damaged lines.
3. Check if the brake discs and friction pads are excessively worn and replace the worn parts.
4. To remove air from the hydraulic system (bleeding operation)

II. Brake Drag (Unable to Fully Release)

Fault phenomenon:

• The brake disc does not rotate flexibly after braking.
• There is obvious resistance when the equipment is moved.
• Abnormal heating of the brake disc

Treatment method:

1. Check if the brake caliper piston fails to retract properly and clean or replace the piston seal.
2. Check whether the free travel of the brake pedal is too small and adjust it to the specified value.
3. Check if the return oil hole of the brake master cylinder is blocked. Clean or replace the master cylinder.
4. Check the gap between the friction plate and the brake disc and adjust it to the standard value.

III. Abnormal Noises or Vibrations During Braking

Fault phenomenon:

• A sharp metallic scraping sound is emitted when braking.
• The equipment vibrates obviously during the braking process.

Treatment method:

1. Check if the brake disc is deformed or unevenly worn. Turn or replace it if necessary.
2. Check if the friction plates are hardened or contaminated with oil. Clean or replace the friction plates.
3. Check if the installation bolts of the brake caliper are loose and tighten them to the specified torque.
4. Check if the hub bearings are worn and replace the damaged ones.

IV. Hydraulic System Faults

Fault phenomenon:

• Excessive or overly soft braking travel

Treatment method:

1. Check whether the hydraulic oil is contaminated or deteriorated, and replace all the brake fluid.
2. Check for leaks in the master cylinder and wheel cylinders of the brakes, and replace any damaged seals.
3. Check if the brake hoses are swollen or deformed, and replace the aged hoses.
4. Re-perform the system exhaust operation.