Mobile Equipment – Brake Repairs and TestingReference Guide (OSHA)

What types of mobile equipment require brake testing? Wheeled, skid-mounted or track-mounted equipment

capable of moving or being moved, except industrial powered lift trucks, shuttle lifts, and/or equipment covered by the Federal Motor Carrier Regulations.

What are the minimum requirements for braking systems on mobile equipment covered by the HBMA advisory – Mobile Equipment – Brake Repairs and Testing?

Self-propelled mobile equipment shall be equipped with a service brake system capable of stopping and holding the equipment with its typical load on the maximum grade it travels.

If equipped, parking brakes shall be capable of holding the equipment with its typical load on the maximum grade it travels.

All braking systems installed on the equipment shall be maintained in functional condition.

How should the service brake test be performed? The test should only be performed on dry, level

roadways. The test should only be performed in areas that are

away from pedestrian and other equipment traffic. Haul trucks and similar equipment should be tested

under normal operating level and weight. Loaders and similar equipment should be tested in an

unloaded condition.

How should the park brake test be performed? The test should only be performed on dry roadways with

grades similar to the maximum grade traversed by the equipment being tested.

The test should only be performed in areas that are away from pedestrian and other equipment traffic.

Haul trucks and similar equipment should be tested under normal operating level and weight.

Loaders and similar equipment should be tested in an unloaded condition.

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What testing protocol is to be used in testing service and parking brakes of equipment covered by HBMA advisory – Mobile Equipment – Brake Repairs and Testing?

The test should be performed with an operator, observer and tester/timer.

Accurately measure a 100-foot section in the center of the 200-foot level test section.

Mark the beginning and end of the 100-foot section with two traffic cones.

Complete a thorough examination/inspection of the equipment to be tested.

Enter the equipment weight on the “Brake Test Report” form.

Perform the test. The operator must drive the equipment through the

test section at a constant speed (between 10 and 20 MPH).

The observer, stationed at the beginning of the test section, must drop his/her arm signaling the tester/timer to begin timing, as the unit enters the 100-foot section.

The tester/timer, stationed at the end of the 100- foot section, must stop timing the unit as it passes the second cone.

As the front of the unit passes the second cone, the operator must apply the service brake bringing the unit to an emergency halt.

Measure the distance from the front of the unit to the second cone and record the results on the “Brake Test Report” form.

Derive the equipment speed using the time recorded and the table on the “Brake Test Report” form. Derive the corresponding braking distance using the chart on the “Brake Test Report” form and the gross weight of the unit. If the tested machine stops in 50 percent or less of

the allowed distance, test the park and foot brake. If the machine requires more than 50 percent of the allowed distance, complete two additional timed passes, compute the average and record the results on the “Brake Test Report” form.

Tag and remove from service any unit requiring more than the allowed distance. Make and document repairs or adjustments and successfully retest the machine before returning it to service.

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Test the park brake and foot brake with the typical normal load on the maximum grade normally traveled by the equipment. If the unit remains stationary while in neutral, with the park brake set, the test is complete. Tag and remove from service any unit on which the park brake does not hold. Make and document repairs or adjustments and successfully retest the machine before returning it to service. Record test results for the service and park brakes on the “Brake Test Report” form.

Upon completion of the brake test, visually inspect seat belt(s) and tethers. Record the findings of the inspection on the “Brake Test Report” form. Replace worn or damaged belts with belts meeting the requirements of SAE J386. Replacement belts must also meet OEM standards. Tag and remove equipment with damaged belts until the belts are replaced in accordance with the HBMA advisory– Mobile Equipment – Brake Repairs and Testing.

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