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Diagnosis and Troubleshooting of Poor Braking Performance in Girder Transport Vehicles
Beam transporter The vacuum-assisted hydraulic braking system primarily consists of the brake pedal, master cylinder, vacuum booster, wheel cylinders, wheel brakes, and brake lines. Its operating principle is as follows: braking force is transmitted via the pedal and linkage to the master cylinder, generating a pressurized fluid at the master cylinder outlet; this pressurized fluid then enters the vacuum booster, where the pressure is further increased before being conveyed through the lines to the wheel cylinders; finally, the hydraulic pressure from the wheel cylinders actuates the brake shoes, forcing them to expand outward and press firmly against the brake drums, thereby producing the braking force.
The braking system of girder transport vehicles frequently experiences four types of failures: brake failure, poor braking performance, brake pull, and delayed braking.
Poor braking performance can manifest in three ways: first, repeatedly depressing the foot brake pedal fails to slow down or stop the girder transporter; second, although the pedal travel appears normal, it feels weak and does not provide immediate stopping power; third, the pedal feels high, stiff, or even bouncy when pressed, yet braking performance remains poor. The troubleshooting methods are as follows:
Air should first be purged from the brake master cylinder and then from the brake wheel cylinders. Air discharged from each wheel cylinder should be purged one by one, starting with the cylinder closest to the brake master cylinder.
If the brakes fail when the brake pedal is depressed once, but the pedal position gradually rises after several presses and the braking performance then improves, this indicates that the pedal free travel is excessive or the clearance between the brake linings and the brake drum is too large. In such cases, first check and adjust the pedal free travel to ensure it is within the specified range, then inspect and adjust the clearance between the brake linings and the brake drum.
If the brake pedal is depressed repeatedly, its position may gradually rise; however, without lifting the foot, the pedal will feel as though it is sinking rather than exhibiting any springiness, indicating a leak in the braking system or a failure of the outlet valve in the master cylinder to seal properly. In this case, inspect the pipe joints for leaks. If leaks are found, they should be tightened, welded, or the affected components replaced. When the pedal is pressed, if its position remains very low—even after several presses—and does not return to its normal height, the most common cause is blockage of the master cylinder’s vent hole or the brake fluid compensation port; these should be inspected and cleared. If the pedal height is within the specified range but, upon pressing, the pedal does not feel spongy or give way under pressure—instead, the braking performance is poor—this suggests a problem with the wheel brakes, and the wheel brakes should be inspected and repaired.
If the brake pedal feels high, stiff, or pulsating when the foot brake is applied, the vacuum booster may be faulty. Before inspecting the vacuum booster, first check that the vacuum hose is intact and that all connections are secure. To perform the test, depress the brake pedal, then start the engine and let it idle for a few seconds. If you notice the brake pedal gradually sinks slightly on its own, the vacuum booster is functioning properly. If the brake pedal does not sink on its own, the vacuum booster is not operating correctly and should be replaced.
Keywords:
Beam transporter
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