Brake System Checks for Heavy Equipment

Sammuel MacMullin | Proven Mining Solutions Inc.

Brakes don’t usually get much attention — until they fail. Whether you’re running haul trucks, dozers, or pipelayers, your braking system is one of the most critical safety systems on any machine.

Routine brake maintenance isn’t just another checkbox — it’s about protecting people, equipment, and uptime.

⚙️ Why Brake Checks Matter

• Safety. Operators depend on brakes every minute of every shift.

• Compliance. Most sites require documented inspections before machines start work.

• Longevity. Spotting pressure loss, leaks, or moisture early prevents costly component failures.

🔎 What to Check in Brake Systems

1. Brake Pads & Shoes

Look for wear, cracking, or glazing. Worn pads reduce stopping power and can damage rotors or drums.

2.Rotors & Drums

Inspect for grooves, heat spots, and uneven wear. Warped surfaces lead to vibration and erratic braking.

3.Lines & Hoses

Inspect for rubbing, leaks, and brittleness — hydraulic fluid or air loss directly reduces stopping force.

👉 Rubbing hoses are one of the leading causes of failure, often due to tight routing. During installation, ensure every hose has clearance so it can’t rub against itself or adjacent lines. When clearance isn’t possible, secure hoses properly with clamps and guards. Good routing and securement are just as important as the fittings themselves.

4. All Braking Systems

All braking systems should be tested under load before operation. Modern heavy equipment can include multiple braking systems — service, parking, emergency — and there’s a variety of ways that these brakes are applied. Each manufacturer has a specific testing procedure for their braking systems. Always refer to the equipment operation manual for the OEM-approved testing process.

5.Master Cylinders & Callipers

Check for leaks and verify even piston movement. A soft pedal or uneven response can signal internal bypassing or a low-set relief valve.

6.Air Systems (Where Applicable)

Inspect compressors, tanks, and valves for leaks or frost buildup. Air systems need clean, dry air to perform reliably.

🧊 Air Dryers – The Forgotten Component

If your equipment uses air brakes, you should have an air dryer. It removes moisture and oil before air reaches valves and chambers — preventing freezing, corrosion, and contamination.

If your unit didn’t come equipped, talk to Proven Mining about aftermarket solutions. We’ve installed and serviced air-dryer systems across a wide range of equipment manufacturers.

✅ Service your air dryer regularly. Replace cartridges, inspect purge valves, and follow OEM intervals. Your air dryer works year-round — not just in the cold months. Neglecting it in summer guarantees problems when winter arrives.

🛠️ Hydraulic Brake Systems & Wear Indicators

Many off-road machines use hydraulic or wet-disc braking systems. They’re powerful, sealed, and durable — but not maintenance-free.

Most designs include wear indicators at the back of the housing — mechanical gauges or measurement ports. Recording these readings regularly helps track wear long before failure.

Always consult the OEM manual for correct measurement tools and specifications.

📏 Pressure Checks & Internal Leak Diagnosis

Brake-pressure checks are one of the fastest ways to gauge system health.

If pressure isn’t holding steady, something’s off — maybe fluid is bypassing internally at a seal, a relief valve is set too low, or another internal leak is developing.

Brake circuits are closed systems, so if fluid isn’t leaking externally, that oil must be going somewhere. Check other oil levels on the machine; if any compartments are rising, that can indicate cross-leakage. For example, on some setups the brake housing bolts directly to the final-drive case, allowing oil to migrate between systems when an internal seal fails. The key is to recognize that every closed system tells a story through its pressure and fluid levels.

💡 In automotive systems, low brake-fluid levels without external leaks can also indicate worn pads. As pads wear, caliper pistons extend further, drawing more fluid from the reservoir and dropping the level. The same principle applies to many hydraulic brake circuits — always inspect both the system and the wear components when low fluid levels are found.

🧰 Operator Tip – Clean Around the Brake Pedal

One of the simplest causes of dragging brakes is dirt. Mud or debris can build up around the brake-pedal drop area, keeping the system slightly applied and overheating brake components. A quick cleanout during daily walkarounds can save you from unnecessary repairs later.

❌ Common Mistakes

• Ignoring soft or spongy brakes

• Skipping air-tank drains or dryer service

• Letting pads or discs wear too thin

• Overlooking hydraulic wear indicators

• Failing to monitor pressure and oil levels

🧠 Pro Tips from the Field

• Use an IR thermometer on brake housings, rotors, and drums after operation — uneven temps mean uneven braking.

• While you’re there, check tire temperatures. A tire running hotter than the rest can point to under-inflation or internal damage.

• Always use the OEM-recommended brake fluid or oil — mixing products can damage seals.

• Air-brake systems benefit from automatic drains, but manual checks should still be part of every shift.

• Train operators to report small changes in brake feel; a “soft pedal” today can become a failure tomorrow.

• OEM manuals remain your best reference for pressure specs, torque values, and service intervals.

• Stay tuned for our upcoming post on tire maintenance — we’ll cover temperature checks, wear patterns, and extending tire life.

  
  

🔧 Proven Mining Has You Covered

For all your heavy-equipment brake-service needs, Proven Mining Solutions keeps your fleet running — and stopping — safely. Ask us about our brake-inspection programs or schedule a system audit today.

📞 587-723-8777

🌐 provenmining.ca