中国 (中文)
Indiabrake disc trouble tracer
brake discs
Incorrect Assembly 1
Appearance
Blue or dark spots on some parts of brake disc, which indicates the local overheating
Cause
Excessive runout of hub. The uneven contact between the brake disc and pads results in excessive sway which causes the local overheating and blueing
Influence
Noise and vibration will gradually increase
Troubleshooting
Calibrate the hub runout to ensure it is in the allowable tolerance range
Incorrect Assembly 2
Appearance
Brake pads will be worn irregularly. Brake pads on one side are heavily worn which those on the other side are slightly worn
Cause
The brake caliper gets stuck. Brake pads on one side rub with the brake disc, which results the metal backplate is worn by the brake pads. The side of disc rubbing with the metal backplate will be greatly scratched, while the other side and the brake pads are almost new
Influence
Harsh noise and vibrations may be generated constantly and the braking performance will be deteriorated. When the vehicle brakes, sideslip may occur due to imbalance
Troubleshooting
Please check, replace or repair the brake caliper. Replace the brake pads and disc if necessary
Incorrect Assembly 3
Appearance
Dirt and/or rusts on the surface of hub
Cause
When installing brake pads, dirt on the hub may result in the improper installation of brake disc; therefore the brake pads will be in irregular contact with the brake disc, causing the irregular wear of the latter
Influence
The thickness of brake disc will become inconsistent, resulting in sway of the disc and generating noises and vibrations. As the use of the brake disc, the situation will worsen
Troubleshooting
Dismantle the brake disc and remove the dirt and rusts on the hub and brake disc. Check if the hub is deformed or damaged. Replace and fasten the brake disc with the tightening torque and in the order recommended by the manufacturer
incorrect assembly 4
Appearance
Cracking or deformation of the contact surface between the brake disc and hub
Cause
The brake disc is excessively fastened and not fastened with the tightening torque and in the order recommended by the manufacturer
Influence
Cracks occur on the contact surface between brake disc and hub. The brake malfunctions completely
Troubleshooting
Check the brake system and related components thoroughly. Replace all faulty components, install a new brake disc and fasten it with the tightening torque and in the order recommended by the manufacturer
incorrect assembly 5
Appearance
Irregular wear of the brake disc’s contact surface and blue spots or even cracks appearing at its center
Cause
The brake caliper and/or pads are installed improperly and the angle of each pad to the brake disc is inconsistent, resulting in a different wearing rate of each side. The friction surface is locally overheating severely, causing blue spot on the surface
Influence
The overheating will gradually result in vibrations and reduce the braking performance
Troubleshooting
Check and repair the brake caliper if necessary. Replace the brake pads and check if the type and shape of the brake pad are suitable for the application
incorrect assembly 6
Appearance
Smaller end of brake disc shearing or breaking at the braking surface of the disc
Cause
Mechanical stress generated due to the misalignment of centers when assembling the brake disc. The brake caliper and disc are improperly assembled or positioned, making the braking surfaces at both sides asymmetric continuously, and finally, the smaller end of brake disc is sheared at the braking surface of the disc
Influence
At the beginning, big noise and vibrations are generated during braking; after the smaller end of brake disc is broken at the braking surface of the disc, the brake will malfunction mechanically
Troubleshooting
Check the brake system and related components thoroughly. Replace all faulty components, install a new brake disc and fasten it with the tightening torque and in the order recommended by the manufacturer. Before installing the brake disc, check the installation position of caliper on the axle
incorrect assembly 7
Appearance
Deformation of contact surface between brake disc and hub and/or its cracking
Cause
Excessive tightening torque used for the set screw
Influence
Vibration occurs from the beginning of braking
Troubleshooting
Replace the brake disc and avoid using excessive tightening torque. Only use the set screws for positioning brake discs
incorrect assembly 8
Appearance
Deformation of contact surface between brake disc and hub or cracking of installation hole
Cause
The brake disc is not tightened in the correct order and the tightening torque is not big enough
Influence
Obvious vibration occurs at the beginning of braking
Troubleshooting
Replace the brake disc and fasten in the correct order with the tightening torque recommended by the manufacturer
abnormal wear 1
Appearance
Excessive wear of brake disc. The thickness of brake disc is less than the “minimum thickness” recommended by the manufacturer
Cause
The brake disc is not regularly inspected or replaced if necessary
Influence
The brake deteriorates and vibration and excessive noise will be generated in braking
Troubleshooting
Check the brake system and related components thoroughly. Replace all faulty components, install a new brake disc and fasten it with the tightening torque and in the order recommended by the manufacturer. Regularly check and maintain the brake disc in the future
abnormal wear 2
Appearance
Brake disc heavily worn with grooves on surface
Cause
Brake pads are excessively or fully worn, making their pads in contact with the brake disc (metal to metal), and thus the surface of brake disc is damaged
Influence
The braking performance is greatly reduced, the braking distance is increased and the harsh noise becomes higher
Troubleshooting
Replace the brake disc and pads. Check the caliper and repair it if necessary
abnormal wear 3
Appearance
Deep grooves occur at the junction of smaller end and braking surface of brake disc
Cause
Excessive wear of brake pads and disc may result in the back plate moving in the caliper. If so, it indicates the backplate of this worn brake pad has been loosening in the bracket (within the caliper) and thus grooves occur at the junction of smaller end and braking surface of brake disc
Influence
The braking performance becomes very low, and the brake pedal travel becomes longer with squeal noise
Troubleshooting
Replace the brake disc and pads. Check the caliper and repair it if necessary
misuse/thermal damage 1
Appearance
Radial cracks or blue spots on the ventilated disc corresponding to the disc’s bars
Cause
The blue spots may indicate the appearance of cracks. This is caused by the metallurgical changes of surface material, and these changes will make the surface material hard and brittle, indicating that the brake has operated exceeding the normal design limits. This may be a result of the frequent or abnormal braking, such as aggressive driving or overloading driving
Influence
The brake efficiency and performance are reduced with noise and vibration generated in braking
Troubleshooting
Replace the brake disc, avoid misuse of the brake system and use the engine more to assist deceleration
misuse/thermal damage 2
Appearance
Brake disc appearing colors with different brightness and chroma (blue, purple and golden)
Cause
The brake disc is not well broken in. This usually occurs after new brake disc or pad is installed and the color of the surface between brake disc and pad will slightly change. If the newly installed brake disc or pad is not well broken in, the friction surface will be overheating, resulting in metallurgical changes of the friction surface.
Influence
The brake efficiency is reduced due to the decrease of frictional force. Besides, vibration will occur and be aggravated with the use of brake pads and disc
Troubleshooting
Replace the brake disc and carry out break-in as per the correct procedures: apply the brake moderately during first 200 km of running
associated components failure 1
Appearance
Deep scratches on brake disc
Cause
Scratches on brake disc are mainly caused by frictional particles between brake pads and disc. These particles may come from outside of the brake system (road, dust, and water) or from the friction material mixed improperly
Influence
Noise will generate when the vehicle brakes or normally runs; the brake efficiency will be reduced due to the decrease of contact surface
Troubleshooting
Replace the brake pads and disc
associated components failure 2
Appearance
The surface of brake disc is contaminated - becomes shiny or has dark spots
Cause
The sediment of friction material is moved to the surface of brake disc. This usually occurs the case when the poor quality brake pads are installed
Influence
Vibration occurs in braking, the brake efficiency is reduced and the brake pedal must be applied with greater force
Troubleshooting
Install high quality brake pads and proper friction material is suitable for the brake and vehicle
Incorrect Assembly 1
Appearance
Blue or dark spots on some parts of brake disc, which indicates the local overheating
Cause
Excessive runout of hub. The uneven contact between the brake disc and pads results in excessive sway which causes the local overheating and blueing
Influence
Noise and vibration will gradually increase
Troubleshooting
Calibrate the hub runout to ensure it is in the allowable tolerance range
Incorrect Assembly 2
Appearance
Brake pads will be worn irregularly. Brake pads on one side are heavily worn which those on the other side are slightly worn
Cause
The brake caliper gets stuck. Brake pads on one side rub with the brake disc, which results the metal backplate is worn by the brake pads. The side of disc rubbing with the metal backplate will be greatly scratched, while the other side and the brake pads are almost new
Influence
Harsh noise and vibrations may be generated constantly and the braking performance will be deteriorated. When the vehicle brakes, sideslip may occur due to imbalance
Troubleshooting
Please check, replace or repair the brake caliper. Replace the brake pads and disc if necessary
Incorrect Assembly 3
Appearance
Dirt and/or rusts on the surface of hub
Cause
When installing brake pads, dirt on the hub may result in the improper installation of brake disc; therefore the brake pads will be in irregular contact with the brake disc, causing the irregular wear of the latter
Influence
The thickness of brake disc will become inconsistent, resulting in sway of the disc and generating noises and vibrations. As the use of the brake disc, the situation will worsen
Troubleshooting
Dismantle the brake disc and remove the dirt and rusts on the hub and brake disc. Check if the hub is deformed or damaged. Replace and fasten the brake disc with the tightening torque and in the order recommended by the manufacturer
incorrect assembly 4
Appearance
Cracking or deformation of the contact surface between the brake disc and hub
Cause
The brake disc is excessively fastened and not fastened with the tightening torque and in the order recommended by the manufacturer
Influence
Cracks occur on the contact surface between brake disc and hub. The brake malfunctions completely
Troubleshooting
Check the brake system and related components thoroughly. Replace all faulty components, install a new brake disc and fasten it with the tightening torque and in the order recommended by the manufacturer
incorrect assembly 5
Appearance
Irregular wear of the brake disc’s contact surface and blue spots or even cracks appearing at its center
Cause
The brake caliper and/or pads are installed improperly and the angle of each pad to the brake disc is inconsistent, resulting in a different wearing rate of each side. The friction surface is locally overheating severely, causing blue spot on the surface
Influence
The overheating will gradually result in vibrations and reduce the braking performance
Troubleshooting
Check and repair the brake caliper if necessary. Replace the brake pads and check if the type and shape of the brake pad are suitable for the application
incorrect assembly 6
Appearance
Smaller end of brake disc shearing or breaking at the braking surface of the disc
Cause
Mechanical stress generated due to the misalignment of centers when assembling the brake disc. The brake caliper and disc are improperly assembled or positioned, making the braking surfaces at both sides asymmetric continuously, and finally, the smaller end of brake disc is sheared at the braking surface of the disc
Influence
At the beginning, big noise and vibrations are generated during braking; after the smaller end of brake disc is broken at the braking surface of the disc, the brake will malfunction mechanically
Troubleshooting
Check the brake system and related components thoroughly. Replace all faulty components, install a new brake disc and fasten it with the tightening torque and in the order recommended by the manufacturer. Before installing the brake disc, check the installation position of caliper on the axle
incorrect assembly 7
Appearance
Deformation of contact surface between brake disc and hub and/or its cracking
Cause
Excessive tightening torque used for the set screw
Influence
Vibration occurs from the beginning of braking
Troubleshooting
Replace the brake disc and avoid using excessive tightening torque. Only use the set screws for positioning brake discs
incorrect assembly 8
Appearance
Deformation of contact surface between brake disc and hub or cracking of installation hole
Cause
The brake disc is not tightened in the correct order and the tightening torque is not big enough
Influence
Obvious vibration occurs at the beginning of braking
Troubleshooting
Replace the brake disc and fasten in the correct order with the tightening torque recommended by the manufacturer
abnormal wear 1
Appearance
Excessive wear of brake disc. The thickness of brake disc is less than the “minimum thickness” recommended by the manufacturer
Cause
The brake disc is not regularly inspected or replaced if necessary
Influence
The brake deteriorates and vibration and excessive noise will be generated in braking
Troubleshooting
Check the brake system and related components thoroughly. Replace all faulty components, install a new brake disc and fasten it with the tightening torque and in the order recommended by the manufacturer. Regularly check and maintain the brake disc in the future
abnormal wear 2
Appearance
Brake disc heavily worn with grooves on surface
Cause
Brake pads are excessively or fully worn, making their pads in contact with the brake disc (metal to metal), and thus the surface of brake disc is damaged
Influence
The braking performance is greatly reduced, the braking distance is increased and the harsh noise becomes higher
Troubleshooting
Replace the brake disc and pads. Check the caliper and repair it if necessary
abnormal wear 3
Appearance
Deep grooves occur at the junction of smaller end and braking surface of brake disc
Cause
Excessive wear of brake pads and disc may result in the back plate moving in the caliper. If so, it indicates the backplate of this worn brake pad has been loosening in the bracket (within the caliper) and thus grooves occur at the junction of smaller end and braking surface of brake disc
Influence
The braking performance becomes very low, and the brake pedal travel becomes longer with squeal noise
Troubleshooting
Replace the brake disc and pads. Check the caliper and repair it if necessary
misuse/thermal damage 1
Appearance
Radial cracks or blue spots on the ventilated disc corresponding to the disc’s bars
Cause
The blue spots may indicate the appearance of cracks. This is caused by the metallurgical changes of surface material, and these changes will make the surface material hard and brittle, indicating that the brake has operated exceeding the normal design limits. This may be a result of the frequent or abnormal braking, such as aggressive driving or overloading driving
Influence
The brake efficiency and performance are reduced with noise and vibration generated in braking
Troubleshooting
Replace the brake disc, avoid misuse of the brake system and use the engine more to assist deceleration
misuse/thermal damage 2
Appearance
Brake disc appearing colors with different brightness and chroma (blue, purple and golden)
Cause
The brake disc is not well broken in. This usually occurs after new brake disc or pad is installed and the color of the surface between brake disc and pad will slightly change. If the newly installed brake disc or pad is not well broken in, the friction surface will be overheating, resulting in metallurgical changes of the friction surface.
Influence
The brake efficiency is reduced due to the decrease of frictional force. Besides, vibration will occur and be aggravated with the use of brake pads and disc
Troubleshooting
Replace the brake disc and carry out break-in as per the correct procedures: apply the brake moderately during first 200 km of running
associated components failure 1
Appearance
Deep scratches on brake disc
Cause
Scratches on brake disc are mainly caused by frictional particles between brake pads and disc. These particles may come from outside of the brake system (road, dust, and water) or from the friction material mixed improperly
Influence
Noise will generate when the vehicle brakes or normally runs; the brake efficiency will be reduced due to the decrease of contact surface
Troubleshooting
Replace the brake pads and disc
associated components failure 2
Appearance
The surface of brake disc is contaminated - becomes shiny or has dark spots
Cause
The sediment of friction material is moved to the surface of brake disc. This usually occurs the case when the poor quality brake pads are installed
Influence
Vibration occurs in braking, the brake efficiency is reduced and the brake pedal must be applied with greater force
Troubleshooting
Install high quality brake pads and proper friction material is suitable for the brake and vehicle