The maintenance of pneumatic disc brakes should be systematically carried out from five aspects: daily inspection, regular maintenance, fault handling, professional operation, and long-term management. Specific measures are as follows：

1、 Daily inspection and cleaning

1. Air supply system inspection
   • Ensure that the air filter is clean, free of moisture and oil stains, and prevent impurities from entering the pneumatic system and affecting performance.
   • Regularly discharge condensed water from compressed air storage tanks to prevent moisture from corroding internal components.
2. Brake appearance cleaning
   • Clean the dust and oil stains on the surface of the brake with a dry soft cloth to prevent blockage of the heat dissipation holes or wear on the components.
   • Check whether there are foreign objects attached to the surface of the brake disc and brake pad, and remove them in a timely manner to avoid slipping or abnormal wear during braking.
3. Tracheal examination
   • Confirm that the trachea is not aging, cracked, or leaking, and that the joints are securely fastened without looseness.
   • Regularly check whether the valves and filters in the air circuit are blocked to ensure smooth air pressure transmission.

2、 Regular maintenance and lubrication

1. Brake disc and brake pad inspection
   • brake discCheck the wear condition every 3 months and measure whether the thickness is within a safe range (usually not less than 1/3 of the original thickness). If there are deep scratches or cracks on the surface, it needs to be replaced.
   • Brake padsCheck the wear indicator or directly measure the thickness. If the wear exceeds the limit value (such as 2mm), it needs to be replaced immediately.
   • Gap adjustmentEnsure even clearance between brake pads and brake discs (usually 0.3-0.5mm) to avoid uneven wear or brake shaking.
2. Seal inspection and replacement
   • Regularly inspect the sealing rings of pneumatic actuators and cylinders for aging, cracking, or air leakage, and replace damaged parts in a timely manner to prevent internal leakage.
   • Clean the area around the seal to prevent impurities from entering and causing seal failure.
3. Lubrication maintenance
   • According to the manufacturer's recommendation, select suitable pneumatic grease (such as lithium based grease) and regularly apply it to moving parts such as pistons and guide pins to reduce wear.
   • The lubrication cycle should be determined based on the frequency of use and environmental conditions (such as lubricating every 6 months or 10000 brake operations).

3、 Troubleshooting and Handling

1. Brake failure or insufficient braking force
   • reasonInsufficient air pressure, severe brake pad wear, air path blockage or leakage.
   • processCheck the air source pressure (usually 0.4-0.6MPa) and adjust it to the normal value; Replace worn brake pads; Clean or replace blocked trachea and fittings.
2. Braking response delay
   • reasonThe air path is too long, the diameter of the air pipe is too small, and the lubrication of the pneumatic actuator is insufficient.
   • processOptimize gas path design (shorten the length of the trachea and increase the diameter); Lubricate the executing mechanism; Check if the control system solenoid valves and sensors are functioning properly.
3. Unable to release after braking
   • reasonInsufficient air pressure, adhesion between brake pads and brake discs, and sticking of pneumatic actuators.
   • processCheck the air source pressure and adjust it; Clean the contact surface between brake pads and brake discs; Disassemble the actuator to check if the piston is stuck, and replace the components if necessary.
4. Abnormal noise or vibration
   • reasonUneven contact between brake pads and brake discs, poor material or severe wear of brake pads, and loose internal parts of pneumatic actuators.
   • processCheck the flatness of the contact surface and replace high-quality brake pads; Tighten the internal components of the actuator.

4、 Professional maintenance operation

1. Brake clearance adjustment
   • Measure the gap between the brake disc and brake pad using a feeler gauge, and adjust the bolt or nut to make the gap even (e.g. 0.3-0.5mm).
   • After adjustment, a brake test is required to ensure no uneven wear or brake shake.
2. Brake noise adjustment
   • Use a decibel meter to detect brake noise (usually ≤ 65dB), and if it exceeds the standard, adjust the noise reduction mechanism (such as tightening nuts and adjusting screws).
   • After adjustment, power on to check if the brake is fully engaged (0.05mm gauge cannot be inserted).
3. Micro switch adjustment
   • Regularly check whether the micro switch signal is normal, and adjust the gap between the contact and the moving iron core through a feeler gauge and multimeter (such as 0.1mm no action, 0.15mm action).
   • After adjustment, repeatedly turn on and off the brake and confirm that the micro switch operates normally.

5、 Long term maintenance management

1. Establish and maintain archives
   • Record the time, results, and handling measures of each inspection, cleaning, and component replacement to facilitate tracking of equipment status and optimizing maintenance plans.
2. Spare parts inventory management
   • Maintain an appropriate inventory of critical components such as brake pads, brake discs, and seals to reduce downtime caused by waiting for spare parts.
3. Operator training
   • Provide professional training to operators to ensure they understand the maintenance points and troubleshooting methods of brakes, and reduce additional costs caused by improper operation.