Section 3H - Hydraulic Brakes

a) metal line and fittings

heavy rust, corrosion or scaling, is present on any metal line or fitting that reduces or increases the thickness, or compromises the structural integrity of the material

level 1 leak of brake fluid

chafing, cracked, flattened or restricting section

insecure mounting causing line to shift out of its normal position

repaired by welding or soldering

repaired using material or method does not meet OEM standard

1, 2, 3, 4, 5, 6

b) flexible line/hose

b) bulged or swells under pressure, flattened, twisted, restricting section or insecure mounting

outer composite material is cracked or chafed exposing an inner layer as shown in Appendix B

deficient product is used that does not meet OEM standard

level 1 leak of brake fluid

1, 2, 3, 4, 5, 6

c) master cylinder

c) damaged or insecure mounting

fluid is contaminated

level 1 leak of brake fluid

fluid level is below indicated minimum level

filler cap is damaged, loose or missing, vent holes are plugged, or gasket is missing or swollen

1, 2, 3, 4, 5, 6

d) pressure differential switch (if equipped)

d) switch or electrical connection is damaged, insecure or loose

level 1 leak of brake fluid

inoperative

1, 2, 3, 4, 5, 6

e) variable or proportioning system

e) link is damaged, missing, or seized

inoperative

level 1 leak of brake fluid

1, 2, 3, 4, 5, 6

f) auxiliary or work brake (line-lock device)

f) any device is installed that interferes with normal service brake operation

1, 2, 3, 4, 5, 6

g) service brake function

g) brake does not apply or release as intended

service brake pedal travel exceeds 80% of the manufacturer's specified available pedal travel or the available pedal travel

1, 2, 4, 5, 6

h) proportioning valve

h) rear wheels fail to lock

1, 2, 4, 5

a) pedal

a) broken, cracked, loose, missing or abnormally worn

welded or repaired in a way that does not meet OEM standard

1, 2, 4, 5

b) mount

b) cracked, deteriorated, insecure or weakened by corrosion

1, 2, 4, 5

c) anti-slip feature

c) ineffective, loose or missing

1, 2, 4, 5, 6

d) hand and foot levers

d) less than 1/3 travel remains as reserve with brakes normally applied, or do not return when released, or not to OEM standards

6

e) accessibility

e) foot brake pedal is not accessible for adequate leverage, or does not have a foot rest for use during braking

6

f) hydraulic brake leakage and pedal reserve test

f) pedal moves slowly in applied direction, any fluid leakage is observed in system

pedal travel from its free height to its depressed height is more than 65% of possible total travel or does not meet OEM specifications

excessive pedal free play

service brake pedal requires pumping to maintain pedal reserve

1, 2, 4, 5, 6

a) brake cam operating lever

a) angle between cam operating lever and actuating cable or rod exceeds 110 degrees in fully applied position; lever repositioned on shaft to compensate for wear; maximum wear indicator exceeded

6

b) cable and adjusters

b) cable frayed with one broken strand; cable or cables routed so as to be restricted by other components; no means for locking brake adjusters

6

c) clevis, pins, rods, couplings

c) any clevis pin, cotter pin, spring, rod clevis or coupling is missing, excessively worn, broken or defective

6

d) sidecar brake (if equipped)

d) not activated by rear brake application, vehicle does not meet regulatory stopping distance

6

a) line, hose and clamp

a) broken, chafed, collapsed, cracked, leaking, loose or missing

insecure mounting, incorrect type, or does not meet the location requirements outlined in Section 1 - Power Train, Item 2h

1, 2, 4, 5

b) check valve

b) incorrectly installed or inoperative, leaking or missing

1, 2, 4, 5

c) tank

c) damaged, structurally deteriorated from corrosion, insecure or loose, leaking or missing

2, 4, 5

d) operation

d) during stage 1 - vacuum reserve is insufficient to assist two full brake applications

during stage 2 - downward movement of brake pedal is not felt when engine is started

1, 2, 4, 5

e) warning device

e) not equipped with an audible or visual signal in the event of failure of air pressure or braking effectiveness

1, 2, 4, 5

f) vacuum pump

f) vacuum pump does not operate within manufacturer specifications, or when no specification is available, is unable to achieve and maintain 4.5 kPa of vacuum

1, 2, 4, 5

a) engine-driven pump, reservoir and belt

a) level 2 leak of hydraulic boost fluid

fluid level is below indicated minimum level, or if not indicated, more than 25 mm from top

filler cap is damaged, loose or missing

1, 2, 4, 5

b) line and hose

b) level 2 leak of hydraulic boost fluid

broken, chafed, collapsed, cracked, loose or missing

insecure mounting or incorrect type

1, 2, 4, 5

c) operation

c) hydraulic assist (boost) is not available or system malfunctions

system does not operate as described in manufacturer service instructions

warning or indicator lamp is activated, showing a system malfunction

during test method 1 - system does not operate as described in manufacturer service instructions or electric driven pump is inoperative

during test method 2 - on a system with gas- accumulator back-up - pedal fails to sink down and then push back up again

1, 2, 4, 5

a) operation

a) system does not operate as described in manufacturer service instructions

downward movement of brake pedal is not felt when engine is started

2, 4, 5

a) operation

a) system does not operate as described in manufacturer service instructions

a vehicle manufactured after 1975 does not have a dual-circuit air system and two independent air-to- hydraulic pressure converters

any system defect or malfunction is detected

2, 3, 4, 5

a) controller operation

a) controller is damaged or defective

controller is seized, or fails to operate brakes when actuated manually

backing/towing function fails to operate as intended

3

b) brake fluid reservoir

b) insecure mounting or loose

level 1 leak of brake fluid

brake fluid level is below ‘fill’ or ‘min.’ mark or less than 75% of capacity when reservoir is not marked

reservoir filler cap damaged, loose or missing

3

c) break-away device

c) missing, damaged, inoperative, improperly installed

3

a) condition and operation

a) damaged or fails to operate as intended

3

a) condition and operation

a) damaged or fails to operate as intended

3

a) wheel magnet and actuator

a) any part is broken, damaged, loose, or missing

magnet is inoperative or seized

3

b) wiring

b) shorted, insulation is cracked or peeled

improperly spliced or connected

not secured at least every 1800 mm

3

c) break-away device

c) see Item 8c in this section

3

d) battery and controller

d) damaged or fails to operate as intended

3

a) operation

a) missing, not either red or amber in colour

does not operate according to manufacturer service instructions

indicates a brake system malfunction or defect

1, 2, 4, 5

a) brake operation

a) a required brake is missing

a brake is inoperative

1, 2, 3, 4, 5, 6

b) brake shoe lining condition (service brakes):

b) broken, cracked, abnormally worn, spalled, contaminated

lining is distorted or separating from shoe

shoe or lining is installed incorrectly (such as primary and secondary shoes reversed)

1, 2, 3, 4, 5, 6

c) brake shoe lining thickness

c) lining:

Bonded Lining

worn to 1 mm or less at the thinnest point

Riveted Lining

worn to 1.6 mm or less above rivet head, or to minimum as indicated by component manufacturer over 1.6 mm

1, 2, 3, 4, 5, 6

d) brake drum condition

d) cracks extend to the open edge of the drum

any external cracks are present

surface crack, groove or worn area that is a structural weakness

hot spots are present in more than one location that cannot be removed by machining within drum limits

discolouration of metal in drum resulting in heat cracks that cannot be machined out within drum limits

friction surface is uneven, chunk broken out of drum

friction surface is abnormally worn, or is hardened and blackened due to overheating (“martensite”)

friction surface is contaminated by grease or oil (Also see section 9 item 4 for wheel seal leaks)

1, 2, 3, 4, 5, 6

e) brake drum diameter (wear)

e) drum has more than one groove worn so that measurement in groove exceeds wear limits:

• out of round more than 0.25 mm on drums 280 mm (11 in.) diameter and smaller

• out of round more than 0.63 mm on drums greater than 280 mm (11 in.) diameter

measured drum diameter exceeds limit indicated on the brake drum, OEM standard or industry standard

if limit is not available:

• for nominal drum size of 350 mm (14 in.) or less: 2.3 mm more than original drum diameter

• for nominal drum size greater than 350 mm (14 in.): 3 mm more than original drum diameter

2.3 mm = 0.09 in.
3 mm = 0.12 in.

1, 2, 3, 4, 5, 6

f) self-adjuster mechanism

f) abnormally worn, incorrect thread direction, inoperative, missing or seized

cable and linkage missing, loose, broken, inoperative

cable frayed

1, 2, 3, 4, 5, 6

g) anchor pin and return spring

g) abnormally worn, bent, broken, loose or missing

spring stretched, bent or no spring tension

1, 2, 3, 4, 5, 6

h) backing plate

h) bent, damaged or loose

shoe contact area is grooved or worn in a manner that restricts free movement of shoes

1, 2, 3, 4, 5, 6

i) wheel cylinder

i) damaged, inoperative or seized, loose or insecure mounting

level 2 leak of brake fluid

dust seal is cracked, damaged, deteriorated, missing, or split

1, 2, 3, 4, 5, 6

j) wheel seal

j) level 2 leak of bearing lubricant

1, 2, 3, 4, 5, 6

a) brake operation

a) a required brake is missing

a brake is inoperative

1, 2, 3, 4, 5

b) brake shoe lining condition (service brakes):

b) a crack extending partially through, or completely through the lining from the friction surface to the metal backing, passing from any rivet hole to the edge

a crack in the edge of the lining that is wider than 1 mm or longer than 38 mm

a piece of the lining is broken off exposing a rivet

lining is distorted or separating from shoe, (e.g.: an object 1 mm thick can be inserted more than 10 mm between the lining and the backing metal)

lining is contaminated by brake fluid, oil or grease (Also see section 9 item 4 for wheel seal leaks)

lining protrudes outside of drum more than 3 mm

lining or any lining fastener is loose - shim is used between lining and shoe

shoe or lining is installed incorrectly (such as primary and secondary shoes reversed)

1, 2, 3, 4, 5

Reject condition 1 – a partial crack in the lining, extending from a rivet hole to the edge

Reject condition 2 – a crack completely through the lining, extending from a rivet hole to the edge

Reject condition 3 – a crack in the edge of the lining wider than 1 mm

Reject condition 4 – a crack in the edge of the lining longer than 38 mm

Reject condition 5 – a piece of the lining is broken off exposing a rivet

Reject condition 6 – lining is distorted or separating from shoe

Pass condition 7 – minor crack or spalling of the lining material

Pass condition 8 – crack in edge of lining shorter than 38 mm

Pass condition 9 – crack in edge of lining less than 1 mm wide

c) brake shoe lining thickness

c) bonded brake shoe lining thickness is less than 2 mm at any point

bolted or riveted brake shoe lining thickness is less than 3 mm at any point

2 mm = 0.08 in.
3 mm = 0.12 in.

1, 2, 3, 4, 5

d) brake drum condition

d) surface crack longer than 75% of the width of the friction surface

surface crack within 25 mm of the open edge

surface crack, groove or worn area that is a structural weakness

external crack

friction surface is abnormally worn, or is hardened and blackened due to overheating (“martensite”)

friction surface is contaminated by grease or oil (Also see section 9 item 4 for wheel seal leaks)

1, 2, 3, 4, 5

e) brake drum diameter (wear)

e) measured drum diameter exceeds limit indicated on the brake drum, OEM standard or industry standard

if limit is not available:

• for nominal drum size of 350 mm (14 in.) or less: 2.3 mm more than original drum diameter

• for nominal drum size greater than 350 mm (14 in.): 3 mm more than original drum diameter

2.3 mm = 0.09 in.
3 mm = 0.12 in.

1, 2, 3, 4, 5

f) self-adjuster mechanism

f) abnormally worn, incorrect thread direction, inoperative, missing or seized

1, 2, 3, 4, 5

g) anchor pin and return spring

g) abnormally worn, bent, broken, loose or missing

spring stretched

1, 2, 3, 4, 5

h) backing plate

h) bent, damaged or loose

shoe contact area is grooved or worn in a manner that restricts free movement of shoes

1, 2, 3, 4, 5

i) axle and spindle

i) cracked

1, 2, 3, 4, 5

j) wheel cylinder

j) damaged, inoperative or seized, loose or insecure mounting

level 2 leak of brake fluid

dust seal is cracked, damaged, deteriorated, missing, or split

1, 2, 3, 4, 5

k) wheel seal

k) level 2 leak of bearing lubricant

1, 2, 3, 4, 5

a) brake operation

a) a required brake is missing

a brake is inoperative

1, 2, 3, 4, 5, 6

b) disc (rotor) condition

b) broken, pitted or damaged

any surface crack extends to an outer edge

crack extends from the friction surface through to the cooling vent

any surface crack is longer than 75% of the radial width, within the friction surface

groove or pitted area in rotor that reduces rotor thickness below minimum allowable value

contact pattern of the pad on solid rotor material (i.e.: not rusted) is less than 75% of the radial width, around the entire rotor, on one side

hot spots are present that cannot be removed by machining

disc not vented properly

friction surface of the rotor is contaminated by brake fluid, grease or oil (also see section 9 item 4 for wheel seal leaks)

1, 2, 3, 4, 5, 6

c) disc (rotor) thickness

c) one groove worn beyond 2.3 mm (3/32 in.)

lateral run-out exceeds 0.125 mm on disc 380 mm (15 in.) diameter or less

lateral run-out exceeds 0.25 mm on discs greater than 380 mm (15 in.) diameter

thickness at any point across the friction surface is less than the minimum indicated on the brake rotor, OEM standard or industry standard

1, 2, 3, 4, 5, 6

d) caliper

d) any part is binding, loose, broken, missing, seized, mounted incorrectly or does not meet the OEM standard

caliper movement within the anchor plate exceeds manufacturer specification, guide is welded or repaired in a way that does not meet OEM standard

any leak of brake fluid

pad retainer is bent, damaged, insecure or missing

boot or bellows is cracked or deteriorated, damaged, or missing

bleeder inoperative

caliper assembly worn beyond OEM specifications

1, 2, 3, 4, 5, 6

e) anchor plate

e) loose or bolt is missing

1, 2, 3, 4, 5, 6

f) pad condition

f) broken, cracked, damaged, spalled, or abnormally worn

friction material is contaminated by brake fluid, oil or grease (also see section 9 item 4 for wheel seal leaks)

friction material loose on pad, pad is missing, or pad is installed incorrectly

rivets loose

1, 2, 3, 4, 5, 6

g) pad (friction material) thickness

g) pad (measured friction material) thickness is less than manufacturer specification, or industry standard

if limit is not available:

• worn to 1.6 mm (1/16 in.) or less at the thinnest
  point on bonded pads

• worn to 1.6 mm (1/16 in.) or less above rivet on
  riveted pads

1, 2, 3, 4, 5, 6

a) brake operation

a) a required brake is missing

a brake is inoperative

2, 3, 4, 5

b) disc (rotor) condition

b) section is broken off or missing

crack extends from the friction surface through to the cooling vent

any surface crack is longer than 75% of the radial width, within the friction surface

any surface crack extends to an outer edge

groove or pitted area in rotor that reduces rotor thickness below minimum allowable value

contact pattern of the pad on solid rotor material (i.e.: not rusted) is less than 75% of the radial width, around the entire rotor, on one side

lateral run-out or out-of-parallelism exceeds 0.3 mm

friction surface of the rotor is contaminated by brake fluid, grease or oil (also see section 9 item 4 for wheel seal leaks) 0.3 mm = 0.01 in.

disc not vented properly

hot spots are present that cannot be removed by machining

2, 3, 4, 5

c) disc (rotor) thickness

c) thickness at any point across the friction surface is less than the minimum indicated on the brake rotor, OEM standard or industry standard

if limit is not available:

• less than 39.0 mm (+/- 0.05 mm)

two grooves worn beyond maximum 2.3 mm
(3/32 in.)

lateral run out exceeds 0.128 mm (0.005 in.) on
discs equal to or less than 380 mm (15 in.) in diameter

lateral run out exceeds 0.25 mm (0.01 in.) on discs
greater than 380 mm (15 in.) in diameter

2, 3, 4, 5

d) caliper

d) any part is binding, broken, missing, seized or mounted incorrectly or does not meet the OEM standard

slide pin/slider or pad slider is binding, damaged, seized, mounted incorrectly, or does not meet the OEM standard

caliper movement within the anchor plate exceeds manufacturer specification, guide is welded or repaired in a way that does not meet OEM standard

level 2 leak of brake fluid

pad retainer is bent, damaged, insecure or missing

boot or bellows is cracked or deteriorated, damaged, or missing

2, 3, 4, 5

e) anchor plate

e) loose or bolt is missing

2, 3, 4, 5

f) pad condition

f) broken, cracked, damaged, or abnormally worn

friction material is contaminated by brake fluid, oil or grease (also see section 9 item 4 for wheel seal leaks)

friction material loose on pad, pad is missing, or pad is installed incorrectly

2, 3, 4, 5

g) pad (friction material) thickness

g) pad (measured friction material) thickness is less than manufacturerspecification, or industry standard

if limit is not available:

• worn to 1.6 mm (1/16 in.) above rivet when wheels and disc removed

• worn to 1.6 mm (1/16 in.) or less at the thinnest point on bonded pads

• worn to 3.2 mm (1/8 in.) or less at the thinnest point on riveted linings

• worn to minimum as indicated by component manufacturer over 1.6 mm

• worn to 3.2 mm (1/8 in.) at thinnest point on riveted pads

• worn to 1.6 mm (1/16 in.) or less above rivet on riveted lining when caliper removed

2, 3, 4, 5

h) clearance between pads and rotor (caliper adjustment)

h) does not meet manufacturer’s specifications

2, 3, 4, 5

a) operation

a) parking brake does not hold in forward and backward gear.

1, 2, 4, 5

b) control

b) binds, broken or missing

inoperative or fails to lock

1, 2, 4, 5

c) cable and/or linkage

c) broken, frayed, improperly secured, missing, seized or equalizer is missing

1, 2, 4, 5

d) adjustment

d) any part of the system is improperly adjusted

1, 2, 4, 5

e) friction material

e) thickness is less than specified by the OEM, or when not specified is less than:

• 3 mm on riveted lining

• 2 mm on bonded lining

2 mm = 0.08 in.
3 mm = 0.12 in.

worn to minimum as indicated by component manufacturer over 1.6 mm

contaminated

1, 2, 4, 5

a) operation

a) parking brake does not hold as required

2, 4, 5

b) airline, connection and fitting

b) fitting, line or repair method does not meet OEM standard

tubing or hose is defective as defined in Appendix B

fitting or connection is broken, cracked, flattened or leaking

damaged in a way (such as: melting, flattening, deformation or kinking) that can restrict air flow

2, 4, 5

c) air tank

c) tank does not meet OEM standard

tank is damaged, loose, welded other than factory weld, or corroded to the extent that structural integrity is compromised

2, 4, 5

d) leakage

d) air leak at any location

2, 4, 5

e) friction material

e) thickness is less than specified by the OEM

when not specified, thickness is less than:

• 3 mm on riveted lining

• 2 mm on bonded lining

2 mm = 0.08 in.
3 mm = 0.12 in.

worn to minimum as indicated by component manufacturer over 1.6 mm

contaminated

2, 4, 5

a) operation

a) parking brake does not hold as required

2, 4, 5

b) line and hose

b) level 2 leak of hydraulic fluid

broken, chafed, collapsed, cracked, leaking, loose or missing

insecure mounting or incorrect type

2, 4, 5

c) release canister

c) damaged, inoperative, insecure, or loose

level 2 leak of hydraulic fluid

2, 4, 5

d) friction material

d) thickness is less than specified by the OEM

when not specified, thickness is less than:

• 3 mm on riveted lining

• 2 mm on bonded lining

2 mm = 0.08 in.
3 mm = 0.12 in.

worn to minimum as indicated by component manufacturer over 1.6 mm

contaminated

2, 4, 5

a) indicator lamp

a) inoperative or missing

fails to turn on during bulb-check cycle when ignition is turned on

indicates the presence of an active malfunction by staying on after the bulb-check cycle

any visual evidence that the system has been tampered with or defeated

1, 2, 4, 5, 6

b) electronic control unit (ECU)

b) insecure mounting, missing or connector corroded

1, 2, 4, 5, 6

c) wiring

c) insecure mounting, missing, or connector corroded

conductor is exposed due to damage, improper repair or other condition of wire

connection or repair does not meet OEM standard

1, 2, 4, 5, 6

d) ABS modulating valve

d) missing, insecure mounting to ECU, level 1 leak of brake fluid or abnormal corrosion

1, 2, 4, 5, 6

e) wheel speed sensor

e) inoperative, insecure mounting, missing, connectors corroded

1, 2, 4, 5, 6

a) indicator lamp/system status

a) lamp fails to illuminate during bulb-check or lamp remains illuminated

fault or malfunction is indicated

any visual evidence that the system has been tampered with or defeated

1, 2, 4, 5, 6