Brakes & Braking System

Brake System Inspection Checklist at KTEO

The brake system evaluation is vital for road safety and encompasses the following key areas:

• Pedal & Hydraulic System: Assesses brake pedal travel and return, brake booster operation, master cylinder, and brake fluid level/condition.

• Hoses & Piping: Inspects rigid and flexible brake lines for leaks, wear, corrosion, cracks, or loose mounting.

• Mechanical Components (Discs, Pads, Drums): Evaluates wear and condition of brake discs, pads, drums, and shoes for excessive degradation.

• Braking Efficiency & Imbalance: Roller brake testers measure braking force per wheel, overall service brake efficiency, and side-to-side braking imbalance on the same axle.

• Parking Brake & Electronics: Checks the performance of the parking brake (manual lever or electronic parking brake) and the operation of the Anti-lock Braking System (ABS), including its dashboard indicator light.

Roller Brake Tester Operation & Evaluation:

• Axle-by-Axle Measurement: The vehicle is placed on roller beds where the braking force of each individual wheel is precisely measured.

• Overall Efficiency: Calculates whether the total stopping force meets the minimum statutory safety thresholds.

• Side-to-Side Imbalance: Compares braking power between left and right wheels on the same axle. Significant variance can cause dangerous vehicle pulling during hard braking.

• Force Fluctuation: Monitors braking consistency. Oscillations in force during rotation indicate warped brake discs or distorted drums.

• Parking Brake: Tested independently to verify its holding capacity and overall efficiency.

Important Note: Subjective driving feel can be deceptive. A severe brake imbalance between sides often goes unnoticed during routine low-speed driving, but is instantly flagged by the roller tester as a major defect

Minimum Service Braking Efficiency Limits for Category M1 Vehicles

Statutory thresholds for total braking efficiency in passenger cars (Category M1) vary based on the date of first registration:

• Category M1 registered after 01/01/2012: Requires a minimum overall braking efficiency of 58%. Any measured value below this standard is recorded as a Major Defect.

• Category M1 registered before 01/01/2012: Requires a minimum overall braking efficiency of 50%. Results below this limit constitute a Major Defect.

• Critically Low Efficiency (Below 50% of the required limit): If the measured efficiency drops below half of the applicable threshold (i.e., below 29% for post-2012 vehicles or below 25% for older vehicles), the defect escalates to a Dangerous Defect.

Summary of Brake System Defect Classifications at KTEO

During the technical brake inspection, overall braking efficiency must meet legal thresholds; failing to do so results in a Major defect (or a Dangerous defect if performance is critically low).

Simultaneously, side-to-side wheel balance on the same axle is evaluated, where a significant difference in braking force between the left and right sides is marked as a Major defect.

Regarding brake lines and flexible hoses, fluid leaks, severe corrosion, or cracks lead to a Major to Dangerous defect, depending on the immediate risk of failure.

For mechanical components (discs, drums, pads), excessive wear or cracks result in a Major defect (with stricter grading if an immediate safety hazard is present).

Finally, an illuminated warning light or malfunction in the ABS system is recorded as a Major defect, while the parking brake is assessed and graded according to its holding capacity and overall mechanical functionality.

Role of KTEO & Visual Inspections for Brake System Wear

A KTEO inspection center does not function as a repair shop and does not replace parts. However, the inspector performs a rigorous visual and measurable check to identify obvious defects that compromise vehicle safety.

Specifically, brake pads and linings must not be worn down past safe operational thresholds, while discs and drums must be free of deep scoring, cracks, or excessive wear that degrades braking performance.

Additionally, there must be no brake fluid leaks from rigid lines, flexible hoses, wheel cylinders, or calipers, and the dashboard warning light for low fluid level or brake system failure must function exactly as intended.

ABS Inspection & Practical Pre-Check Advice

The Anti-lock Braking System (ABS) is an essential component of the brake test whenever the vehicle is equipped with it. An illuminated ABS warning light on the dashboard indicates a system malfunction and is flagged as a major defect, meaning it should never be ignored prior to inspection.

Practical Tip: Visit a qualified repair shop immediately if you notice an active ABS or BRAKE warning light, an excessively "spongy" brake pedal, noticeable pulling to the left or right when braking, or any visible brake fluid leaks.

Pre-Inspection Brake System Checklist

• Warning Lights: Ensure that the ABS light, brake system warning light, or any other related dashboard indicator does not remain illuminated.

• Brake Fluid: Check the brake fluid reservoir level according to the manufacturer's guidelines.

• Pedal Feel: Pay attention to pedal travel and responsiveness — it should not feel excessively soft ("spongy") or unusually stiff.

• Parking Brake: Test that the parking brake (manual or electronic) engages properly, holds the vehicle securely, and releases fully.

• Braking Behavior: If the vehicle pulls to one side, vibrates during braking, or produces a metallic scraping sound, have it serviced prior to inspection.

• Wear & Tear: If you know the brake pads, discs, or drums are near their service wear limits, have them inspected and replaced before the KTEO test.

Defect Classification & Consequences in KTEO Testing

Defects identified during a vehicle inspection are categorized into three severity levels based on their impact on road safety and the environment:

• Minor Defects: Minor faults or discrepancies that do not pose an immediate safety risk. The vehicle passes the inspection, a roadworthiness certificate is issued, and the owner is required to repair them without a mandatory re-inspection.

• Major Defects: Significant failures that impair safety or environmental performance. The vehicle fails the inspection, a statutory window (typically 30 days) is granted for repairs, and a re-inspection is required.

• Dangerous Defects: Direct and immediate hazards to road safety or the environment. In these cases, strict vehicle operation restrictions or prohibitions apply until all critical defects are rectified and verified through a re-inspection.

Regulatory Framework & Legislation for Brake Systems in KTEO

The legal framework governing the technical inspection of braking systems is established by the following regulations:

• Ministerial Decision 340141/2022 (Government Gazette 5759/B/10.11.2022): Replaced Annexes I and II of Decision 19111/192/2019. It serves as the primary reference for the "Brakes & Braking System" section on eKTEO, centered on Annex I (Section 1: "Braking Equipment"), which covers mechanical condition, operation, service brake efficiency, secondary braking, parking brake, and related electronic systems.

• Ministerial Decision 19111/192/2019 (Government Gazette 1003/B/26.03.2019): Defines the procedures, methodology, and certification required to conduct periodic, extraordinary, and voluntary inspections at public and private KTEO centers.

• Joint Ministerial Decision 49372/3352/2017 (Government Gazette 2726/B/04.08.2017): Establishes the core Greek framework for periodic roadworthiness testing of motor vehicles and trailers, in compliance with EU directives.

• Directive 2014/45/EU (Annex I): Sets European Union minimum standards for inspection items, testing methods, and minimum braking efficiency limits per vehicle category.

Important Note: Exact requirements and defect gradings depend on vehicle category, first registration date, brake system type, and specific test findings. This guide is informational and does not replace official statutory texts or the technical judgment of the KTEO inspector.