Umair Gaines
Electric brakes are commonly fitted on caravans due to their affordability and basic design. They use electrical signals, electromagnets, and brake pads to help the caravan stop while towing. Caravan brakes should be checked and adjusted regularly, especially if the caravan is new or subject to extreme use. This can be done by using a star adjustment wheel to change the clearance between the shoe and the drum. Alternatively, self-adjusting electric brakes can be adjusted by operating them with the manual lever on the brake controller.
Characteristics and Values Table for Adjusting Electric Brakes on a Caravan
| Characteristics | Values |
|---|---|
| Type of brakes | Electric drum brakes |
| Frequency of adjustment | Every 3,000 miles or 3 months |
| Tools required | Trailer brake spoon, brake adjustment tool, or flathead screwdriver |
| Adjustment mechanism | Star wheel adjuster |
| Adjustment process | Pry down on the brake spoon handle to tighten the brake pads; pry upward to loosen |
| Number of clicks | Turn the wheel one click at a time |
| Testing | Spin the tire between each click to ensure it spins freely |
| Final check | Tire should spin freely with a slight scraping sound, indicating proper engagement |
| Additional maintenance | Inspect and clean the backing plate, magnet arm, brake magnet, and brake shoes |
| Replacement parts | Magnets and shoes; inspect magnet arms and adjuster springs for wear and replace if needed |
| Proportional brake controllers | Need to be installed at a specific angle or set up manually to suit the angle of installation |
| Time-delay brake controllers | Can be mounted at any angle and adjusted from the driver's seat |
| Self-adjusting brakes | Can be adjusted using the manual lever on the brake controller while driving at ~20 mph |
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What You'll Learn
Adjusting brake shoes within the drum
Adjusting the brake shoes within the drum of electric brakes on a caravan is a straightforward process, but one that requires regular attention to ensure the brakes are operating correctly and safely.
Firstly, it is important to understand that brake shoes will bed in when you first get them and will wear during use, so regular adjustments are necessary. You will know when to adjust the brake shoes when you notice that the caravan is pushing the tow vehicle when you brake. This can be dangerous and can cause a sway, so it is important to act quickly.
To adjust the brake shoes within the drum, you will need to use the star adjustment wheel to change the clearance between the shoe and the drum. This adjustment mechanism lengthens when turned one way, pushing the shoes closer to the drum, and shortens when turned the other way, moving the shoes away from the drum. You can use a trailer brake spoon, brake adjustment tool, or flathead screwdriver to turn the star wheel adjuster inside the brake chamber. Push down on the brake spoon handle so the adjuster wheel is pried upward, tightening the brake pads or shoes. Turn the wheel one click at a time, spinning the tire between each click to make sure it spins freely. Once the tire becomes difficult to turn, stop tightening the adjuster. If you need to, you can pry upward on the adjustment tool to loosen the adjuster wheel. The tire should spin freely but still have a slight scraping sound, indicating that the trailer brake pads are properly engaged.
If your caravan is new, it will require more frequent initial checks and adjustments to ensure the brakes are correctly operational. If your caravan is subject to extreme use, you should also increase the frequency of checks and adjustments.
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Using a star adjustment wheel
Adjusting the electric brakes on a caravan is a crucial safety measure that should not be overlooked. Electric drum brakes are a common feature on caravans due to their affordability and simple design. To adjust them, you'll need to use the star adjustment wheel, which alters the clearance between the brake shoe and the drum.
First, ensure the caravan is securely supported and the handbrake is released. Rotate each wheel to check for any drag, which could indicate the need for adjustment. If there is resistance, remove the wheel and locate the small green bung on the backplate. Lift this off to access the adjuster.
Now, for the star adjustment wheel: you'll need to turn it in one direction to push the brake shoes closer to the drum and the opposite direction to move them away from the drum. This mechanism gets longer when pushing the shoes towards the drum and shorter when moving them away. Turn the star wheel until you feel resistance in turning the wheel, and then turn it the other way until you hear a slight constant drag on the brakes.
It's important to note that the star wheel should be turned upwards to tighten the brakes and downwards to loosen them. However, some users have reported conflicting experiences, so it's always best to consult the manufacturer's instructions or a professional if you're unsure.
Finally, once you've adjusted both sides, check the handbrake operation. For a ratchet handbrake, pull it on by one or two clicks, then ensure both drums meet the same resistance when turned. If all is well, replace the green bungs and wheels, and torque the wheel nuts according to your caravan handbook.
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Maintenance and cleaning
Maintenance
- Regularly inspect and maintain the brakes, including annual servicing.
- Before adjusting the brakes, ensure the caravan is secure: apply the handbrake, extend the hitch, and raise the corner steadies.
- Loosen the wheel bolts and jack up the caravan to access the brakes.
- Adjust the brake shoes within the drum using the star adjustment wheel to change the clearance between the shoe and the drum.
- Check the operation of the handbrake: apply it fully and ensure the balance bar is at a 90-degree angle to the rod, with both sides pulling evenly.
- Inspect the magnet arms, brake magnet, and brake shoes for any wear or damage, replacing them as needed.
- If your caravan has a time-delay braking system, ensure that the braking force is adjusted correctly based on factors such as load changes and weather conditions.
- Ensure that the compensators are at 90 degrees to the brake rod when the brakes are applied, and adjust the cable locking nuts if there is any misalignment.
- Check the travel of the individual brake cables; it should be between 2 and 5 mm.
- Verify that all drums spin freely to ensure there is no resistance or drag.
Cleaning
- Clean the internal components of the brake drum, including the backing plate, magnet arm, brake magnet, and brake shoes.
- Remove brake dust from within the brake drum, as it can accumulate due to the lack of ventilation in caravan brakes.
- Re-grease the internal components of the brake drum after cleaning.
Remember to consult a professional if you are unsure about any maintenance or cleaning procedures, as improper adjustments can affect the safety and performance of your caravan's brakes.
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Self-adjusting brakes
To begin the break-in process, drive your caravan to an open area, such as an empty parking lot. Accelerate to around 40 mph and then use the manual override on your brake controller to slow down to a stop without using the brake pedal. Repeat this process about 20 to 30 times to properly seat the brakes. After the initial break-in, it is recommended to adjust the brakes again after the first 200 miles, and subsequently, every 3,000 miles or 3 months, whichever comes first.
During the break-in process, you may need to inspect and clean certain components, such as the backing plate, magnet arm, brake magnet, and brake shoes. It is important to replace any worn or scored magnets and shoes to ensure adequate braking performance. Additionally, inspect the magnet arms for any loose or worn parts, and check the shoe return/adjuster springs for any stretch or deformation.
While self-adjusting brakes reduce the need for frequent adjustments, it is still important to regularly check and maintain your caravan's braking system. Always refer to the manufacturer's recommendations and safety guidelines when working on your caravan's brakes.
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Troubleshooting
Before adjusting your electric caravan brakes, ensure that the caravan’s handbrake is applied and the hitch is fully extended. Loosen the wheel bolts before jacking up the caravan. Wind up the corner steadies to prevent damage while jacking up the van. Once the caravan is supported high enough, lower the corner steadies to give extra support and stability.
If you notice that one wheel is hotter than the other, it is likely that there is an issue with the cooler wheel. Brakes need to get hot, and if they don't, it means they are not working effectively. If there is any drag, you may need to delve deeper into the braking system.
If your trailer or caravan has a copper brake line, it may rust over time, causing the line to become brittle, crack, and leak. Caliper pistons can also seize due to a lack of fluid pushing the piston. This can cause the ‘o’ ring inside the caliper and the caliper rubber boot to crack, leading to leaks.
Brake pads can rust onto the disc if the handbrake has been left on for an extended period, and they can also wear down over time due to usage. Electric brakes require a brake control unit to be fitted to the tow vehicle for them to function. If your trailer plugs have corroded pins and wires, this can affect the power supply to the brakes.
If your caravan weighs between 750kg and 2000kg Gross Trailer Mass (GTM), it must have a braking system on the wheels of at least one axle. Any trailer weighing from 2001kg to 4500kg GTM must have a braking system on all wheels.
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Frequently asked questions
It is recommended that you check and adjust your caravan brakes every 3,000 miles or 3 months. New caravans may require more frequent checks and adjustments.
You can adjust your electric caravan brakes using a trailer brake spoon, brake adjustment tool, or flathead screwdriver.
Use your tool of choice to turn the star wheel adjuster inside the brake chamber. The adjuster is typically located below the brake drum. Push down on the brake spoon handle so the adjuster wheel is pried upward, tightening the brake pads or shoes. Turn the wheel one click at a time, checking that the tire spins freely after each click. Stop tightening when the tire becomes difficult to turn.
If your electric brakes are not self-adjusting, you can manually adjust them using the lever on the brake controller. While travelling at a slower speed of around 20 mph, apply the brakes fully with the lever and release. Repeat this process several times, ensuring that you do not overheat the brakes.
