Breaking Down Brake Maintenance: Critical Safety Checks Every Fleet Should Perform

In commercial transportation, there are not many systems more critical to safety than the brakes on your fleet of vehicles. Most fleet management tools will focus on the best route for your drivers, and fuel performance for your fleet, but brake maintenance and safety are and will always be first and foremost to make sure you have safe vehicles on the road and regulatory compliance.

At Kooner FMS, we understand that taking care of your brakes is more than just failing inspections and complying with regulations, it is about ensuring the safety of your drivers, your loads, and your reputation. Let’s talk about brake safety regulations that should be a part of your fleet maintenance & repair program.

The Cost of Brake Failures

Prior to commencing your maintenance, identify where those costs may exist. The Federal Motor Carrier Safety Administration indicates that nearly half of all defects in roadside check inspections are brake defects. In addition, the Commercial Vehicle Safety Alliance states that commercial vehicles with major brake defects are more than three times as likely to crash.

According to FMCSA data from 2023, there were 6 of 20 violations that are brake-related. The CVSA reported that during 2024 Brake Safety Week, out of 16,725 inspected vehicles, 12.8% were taken out of service for brake defects.

Essential Brake System Inspections

Implementing a sound brake maintenance program is essential for the safety of the fleet and regulatory compliance. It includes: daily driver inspection, weekly air system inspection, monthly brake component inspection, and a performance test under brake demand, once per quarter, which allows for a clear forward-looking process.

1. Daily Driver Inspections

Drivers are to notify their supervisor as soon as they experience issues so that they can be fixed when they are simple issues instead of major repairs, or losing a truck for several days while it gets repaired. Regular checks and last-mile maintenance help to improve safety. The driver training for the daily brake inspection should include the following key tenets:

• Air pressure buildup time

• Proper pressure levels (typically 90-120 PSI)

• Audible air leaks

• Warning signals on the dashboard

• Unusual brake pedal feel or response

2. Weekly Air Systems Inspection

If you are planning on "skipping" maintenance on a big truck air system, so expect to defer on-site fleet repairs and maintain your truck's rolling, you may want to have a plan for unexpected repairs while on the road. A simple inspection of the air system for leaks and wear will save you hassle.

Systematic inspection, repair/replacement, and draining moisture is always better than brake repairs and downtime for your truck.

• Drain the air tanks and remove any moisture and contamination

• Check the airlines for excessive chafing, cracking, and improper securing.

• Check the air dryers and replacement cartridges in accordance with the manufacturer's recommendations.

• Check to ensure that the low air warning device activates at the correct low-point PSI (which is usually 55-65 PSI).

3. Monthly Brake Part Checks

I cannot stress this one enough. Ensuring your brakes are in good condition is all about catching the issue early, so that you can fix things before they become more complicated, provide safety to the drivers, and keep your fleet of trucks in operation. You will want to look at the following:

• Brake pads and shoes. Replace as appropriate when getting thin (approximately 1/4 inch or as per the manufacturer).

• Brake drums and rotors. Inspect for cracking or scorching/odd wear patterns.

• Brake chambers. Inspect for damage, distribution, and leakage.

• Slack adjusters. Inspect for functionality and adjust as necessary.

• S-cam bushings and all that stuff. Inspect for wear.

4. Quarterly Brake Performance Testing

Checking is not enough. You should see the actual performance of those brakes. These tests will reveal problems before they are too costly or dangerous. All truck management companies should carry out regular brake performance testing:

• Measure the stroke on all axles

• Conduct stopping distance tests in controlled conditions

• Have brake test equipment to measure braking efficiency

• Track and review discrepancies between axles

Seasonal Factors

Weather can be a significant factor in brake operation, and the length of time that they will last. You should then change your maintenance to suit the season, regardless of what environmental conditions you are dealing with, to ensure safety and prevent premature component failure.

Heat Stress on Summer Brakes

Braking systems on commercial vehicles are seriously impacted by excessive temperatures, which can lead to accelerated wear of components, reduced braking performance, and extended stopping distances.

• Monitor for brake fade after long downhill runs

• Look for glazed brake linings that indicate overheating

• Ensure cooling airflow is free from debris.

Winter Brake Maintenance

Winter can wreak havoc on your vehicle brakes due to moisture, freezing temperatures, and those horrible salty road treatments. Preparing your fleet for winter is crucial to decreasing breakdowns and lowering your costs. Even plain cold weather can affect some totally surprising things you need to address.

• Check air dryers before moisture develops.

• Check heating elements in air systems.

• Replace your drain valves with winter-grade drain valves to prevent freezing.

When to Call for Assistance

True brake problems can happen at any time, even with proper maintenance. Fixing the problem quickly can keep small issues from becoming major emergencies. Some brake problems require immediate professional attention. If emergency road assistance needs are necessary, consider this when:

• ABS lights remain on

• Braking is uncentered or pulling

• Air drops off unexpectedly while operating

• Unusual noises (grinding, air leak) occur

• Stopping distances increase considerably

Creating a Brake Maintenance Calendar

Brake systems can fail, even with regular and proper maintenance. A proactive approach to addressing brake problems is better than embracing a reactive approach; the sooner you can address problems, the better!

Here are a few options for emergency roadside assistance:

• Daily pre-trip and post-trip inspections on each vehicle in the fleet

• Weekly or daily checks of the air system (if equipped on the vehicle)

• Monthly inspections of components

• Quarterly performance tests

• Once every two years, full brake overhaul

Fleets that maintain structured brake maintenance programs can reduce brake breakdowns by 37%, based on maintenance industry data, and fleets save approximately $0.04 per mile worked.

The bottom line is, your fleet brake strategy has a direct consequence on your bottom line. A single roadside breakdown involving a truck and roadside assistance can cost $800 or more, not including lost productivity or lost delivery time. Preventative maintenance for fleets and commercial vehicles is not just safer, it is smarter business.

Conclusion

Kooner FMS handles everything for fleet operators and ensures that their vehicles work at their best and that their drivers remain safe. We provide solutions for vehicle maintenance, as well as emergency service for large vehicles. Our focus is on optimizing fleet performance.

A little wisdom: when it comes to brake systems...be proactive instead of reactive. It is not just your drivers and your business- everybody on the road depends on it!

Keep your fleet rolling safely! Learn essential brake checks & fleet maintenance tips to avoid breakdowns, save costs, & ensure driver safety.