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Brakes in Construction Machinery: Disc Brakes vs. Wet Inboard Brakes | A Complete Guide
Brakes in Construction Machinery: Disc Brakes vs. Wet Inboard Brakes | A Complete Guide
The Most Important Safety System
The braking system in construction machinery is the most important safety system, on which the life of the operator and bystanders depends. Its proper functioning is non-negotiable. In heavy equipment, from JCB backhoe loaders to large Volvo wheel loaders, we mainly encounter two types of service brakes: traditional disc brakes and the much more powerful wet multi-disc brakes integrated into the axle. Understanding their design, wear symptoms, and service principles is fundamental to professional maintenance.
System 1: Dry Disc Brakes
This system is well-known from cars but works under much heavier loads in construction machinery. It is mainly used in smaller machines like backhoe loaders or telehandlers.
Design and Operation
The system consists of a brake disc attached to the wheel hub and a caliper with pistons and brake pads. Pressing the brake pedal increases pressure in the system, the pistons in the caliper extend and press the pads against the disc, slowing the machine. In heavy equipment, pedal pressure is often air-assisted (servo).
Anatomy of a Brake Pad
A brake pad is an advanced composite. It consists of a metal backing plate, a vibration-damping shim, and a friction compound. The composition of the latter is a manufacturer's secret but includes sintered metal fibers, resins, and ceramic additives to ensure a high friction coefficient and resistance to extreme temperatures.
Common Problems and Diagnostics
- Glazed Pads: The most common operator error is prolonged, light braking on downhill slopes. This overheats the friction material and creates a hard, glassy surface that drastically reduces braking effectiveness.
- Caliper Leaks: Whenever replacing pads, carefully inspect the condition of the dust boots and piston seals. Even the slightest fluid leak onto the pads or disc disqualifies them from use.
System 2: Wet Multi-Disc Brakes (in Axle)
This solution is used in heavier machines (large wheel loaders, articulated haulers like CAT, Komatsu) where braking forces are immense and reliability must be absolute.
How Do They Work?
The entire mechanism is enclosed inside the axle housing and submerged in oil. It works like a clutch in a Powershift transmission – it consists of a pack of alternating friction plates and steel separator plates. Pressing the brake pedal causes a hydraulic piston to compress this pack, generating powerful braking force. The oil in the axle cools and lubricates the entire system.
Common Problems and Diagnostics
- Shavings in the Axle Oil: This is a key diagnostic indicator. Dark dust indicates worn friction plates, while metallic shavings point to wear on the steel plates or, worse, other components of the differential.
- Oil Overheating: Can indicate continuous, light friction in the brake pack (e.g., due to poor adjustment) or it slipping under load.
Crucial Service Tip: Soak the Discs!
Before installation, new friction plates must be soaked in the axle oil for at least 24 hours. This process allows the friction material to become fully saturated with oil. Installing them "dry" will cause the surface to glaze over during the first braking application, drastically reducing braking effectiveness and shortening their life.
FAQ - Frequently Asked Questions
1. What brake fluid should I use?
It depends on the machine! Many backhoe loaders use a special LHM mineral oil, not standard DOT fluid. Using the wrong fluid will destroy all seals in the system. Always check the manual!
2. Should brake pads be replaced in pairs?
Yes, absolutely always. Brake pads on a single axle should be replaced as a complete set (on both wheels) to ensure even braking force.
3. What is a parking brake?
It's a secondary brake used to secure the machine when parked. It is often a small disc brake mounted on the driveshaft rather than directly at the wheels.
Brake performance is your priority. Don't cheap out on parts.
Regular service and the use of high-quality parts are the foundation of safety. Our offer includes everything you need for your brake system service: from brake pads and discs, through plate kits for wet brakes, to caliper seal kits from the VICORTEX brand. Also remember about clean oil and REDX filters. Contact us!
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