Otis Singleton
Electric trailer brake controllers are devices that allow drivers to operate the trailer brakes independently of the vehicle brakes. There are two common methods of applying the trailer brakes with an electric brake controller: User-Controlled and Proportional (or inertia sensing). The User-Controlled method is a basic technique where the driver adjusts the braking force via an interface with the controller. In contrast, the Proportional mode uses accelerometers to provide accurate braking measurements and deliver optimal braking in response to the vehicle's braking force. When adjusting electric trailer brake controllers, it is crucial to ensure that the trailer brakes slow down the vehicle without locking up the trailer wheels. This can be tested by gradually increasing the gain and pulling the manual lever until the brakes lock, then reducing the setting by one point. Adjustments may also depend on factors such as load weight, temperature, and road conditions.
Characteristics and Values of Electric Trailer Brake Controller Adjustment
| Characteristics | Values |
|---|---|
| Speed | Test at 25-30 mph |
| Foot Pedal | Do not press the foot pedal during the test |
| Brake Locking | Adjust the controller so that the brakes do not lock |
| Trailer Behaviour | Adjust the controller so that the trailer follows the same line as the vehicle |
| User-Controlled | User adjusts the braking force via an interface with the controller |
| Proportional | Advanced controllers use accelerometers to provide accurate braking measurement |
| Manual Lever | Pull the manual lever to test the brakes |
| Temperature | Consider the temperature of the brakes before making adjustments |
| Brake Controller Setting | Set the controller to heavy electric or light electric |
| Gain | Increase the gain until the desired braking power is achieved |
| Brake Engagement | Set the controller to fully engage the trailer brakes |
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What You'll Learn
Adjusting new trailer brakes
Adjusting your trailer brakes is important for towing safely. Electric trailer brakes use electrical signals, electromagnets, and brake pads to help the trailer stop while towing. The built-in electromagnets draw power from the vehicle to squeeze the brake pads. As power increases, the electromagnets apply more stopping force. To regulate the power to the electric trailer brakes, a brake controller is used. This is an electronic device that allows the driver to monitor and control the trailer brakes.
Most trailers have a cover, cap, or plug that needs to be removed to access the trailer brakes. They are typically made from plastic or rubber and can be pried out with a flat-head screwdriver. Once the cover is removed, you will have access to the brake chamber and the adjustment wheel.
Using a trailer brake spoon, brake adjustment tool, or flat-head screwdriver, 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. This will tighten the brake pads or shoes. Turn the wheel one click at a time, spinning the tire between each click to ensure it spins freely. Once the trailer 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.
To loosen the trailer brakes, turn the adjuster back, prying it downward. The star wheel adjuster should be tightened so that the trailer tire turns freely and a slight scraping sound is heard.
It is recommended that you check and adjust your trailer brakes every 3,000 miles or 3 months, depending on how often you tow your trailer. Additionally, when testing your trailer brakes, ensure that the trailer brakes slow the vehicle down without locking up the trailer wheels. Test several times until you get a feel for your trailer and the loads you typically carry.
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User-controlled vs. proportional braking
When it comes to braking setups, there are two main types of brake controllers: user-controlled (time-delay) and proportional. Both work to bring the vehicle-trailer combination to a stop, but they differ in their activation methods and features.
User-controlled or time-delay brake controllers are characterised by their simplicity in design and operation. They do not have any internal moving parts, which makes installation and mounting more flexible. This type of controller can be installed virtually anywhere on the dash or below it, without the need to worry about precise physical orientation. User-controlled brake controllers activate the trailer brakes based on timing. From the moment the brake pedal is pressed, a time-based unit is designed to activate the electric trailer brakes by an increasing amount over a set period. There is a delay between the initial application of the brakes and the time it takes for the controller to reach maximum power output. This delay can be adjusted by changing the sync setting.
On the other hand, proportional brake controllers are more adaptive and responsive. They utilise an internal inertia-based sensor or accelerometer to detect the deceleration of the tow vehicle. This sensor translates physical forces into electrical signals, which then determine the amount of braking power applied to the trailer brakes. The key advantage of a proportional controller is its ability to adapt to different braking situations. For example, if you need to slam on the brakes, the trailer brakes will activate with the same intensity, ensuring a uniform and smooth braking experience. The amount of braking power and the rate of application can be adjusted to fit personal preferences, road conditions, trailer type, and load size.
While user-controlled brake controllers offer simplicity and flexibility in installation, proportional brake controllers provide a more dynamic and adaptive braking experience. The choice between the two ultimately depends on specific user requirements, preferences, and towing conditions.
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Testing trailer brakes
Testing Brake Functionality
Firstly, it is essential to test the basic functionality of the trailer brakes. This can be done by following these steps:
- Consult your trailer brake controller's manual to understand the specific controls and recommendations.
- Ensure that the trailer wiring harness is securely plugged into your vehicle.
- Engage the parking brake on your vehicle for safety.
- Utilize the manual activation button on the trailer brake controller to activate the trailer brakes. This feature is available on most controllers and allows you to test the brakes without applying the vehicle brakes.
- Inspect the trailer brakes to ensure they are functioning correctly.
Testing Brake Performance
Once the basic functionality is confirmed, you can proceed to test the performance of the trailer brakes:
- Couple your trailer to your vehicle and find a suitable testing area, preferably a flat, level surface.
- Start with the gain level and sensitivity settings recommended by the manufacturer, as these settings are crucial for matching the trailer and load size.
- Drive at a slow speed, around 1-5 mph, and slowly release the accelerator without applying the vehicle brakes.
- Observe whether the trailer brakes can slow down the vehicle smoothly without locking up the trailer wheels.
- Repeat this test several times to get a feel for how the trailer brakes perform with the loads you typically carry.
- Gradually increase your speed during subsequent tests to ensure smooth stops at various speeds.
Troubleshooting and Fine-Tuning
If you encounter issues during testing or feel that adjustments are needed, consider the following:
- Refer to the troubleshooting section of your trailer brake controller's manual for specific instructions.
- Ensure that the trailer brake controller is properly connected and mounted in the cab of the vehicle.
- Verify that the blue brake power output wire from the controller to the trailer brakes is intact and connected, as this wire is essential for brake activation.
- Adjust the gain setting to accommodate the specific trailer and load. For larger trailers or heavier loads, increase the gain setting, and for smaller trailers or lighter loads, decrease it to avoid brake lockup.
- If issues persist, consider using a circuit tester, such as the one recommended by the manufacturer, to check for any faults in the brake controller or the output circuit.
Remember, testing and adjusting trailer brakes is a process of trial and error, and it may take a few attempts to find the optimal settings for your specific setup. Always prioritize safety and consult experts or mechanics if you have any doubts or concerns.
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Manual brake levers
Understanding Manual Brake Levers
Adjusting the Manual Brake Lever Settings
To adjust the manual brake lever settings, follow these steps:
- Start with Manufacturer Recommendations: Begin by consulting the manufacturer's instructions for your specific brake controller model. They usually provide initial settings or a recommended starting point for the power setting. For example, Tekonsha's Prodigy P2 controller suggests setting the power at "6" as a starting point.
- Find an Open Space: Locate a spacious area, such as an empty parking lot or a flat stretch of pavement, where you can safely test and adjust your trailer brakes without obstacles.
- Reach the Recommended Speed: Drive your vehicle with the trailer attached and reach the recommended speed suggested by the manufacturer. For some controllers, this speed may be around 25 mph, while others may suggest a higher speed, such as 40-45 mph, to ensure the device is warmed up for accurate adjustments.
- Engage the Manual Brake Lever: While maintaining the recommended speed, firmly pull the manual override lever on the controller to its maximum position, typically all the way to the left. Do not apply the brakes on the tow vehicle during this step.
- Adjust Power and Test Brake Response: With the manual override lever engaged, adjust the power control knob or settings according to the manufacturer's instructions. Observe how the trailer brakes respond. If the trailer brakes lock up, reduce the power level slightly. If they don't respond at all, increase the power a notch. Repeat this process until you find the optimal setting where the brakes respond effectively without locking up.
- Fine-Tune as Needed: Depending on your load weight and trailer size, you may need to fine-tune the settings. Larger trailers and heavier loads may require higher power settings, while smaller trailers may need lower settings to avoid brake lockup. Refer to the manufacturer's guidelines for specific recommendations.
- Test on Different Surfaces: Consider testing and adjusting your trailer brakes on different surfaces, such as gravel or pavement. Gravel roads can help you hear and see if your trailer skids during braking, providing valuable feedback for adjustments.
- Pre-warming Brakes: Refer to your manual for instructions on pre-warming your brakes before making adjustments. This step can help you dial in the right setting for optimal performance.
Additional Considerations
When working with manual brake levers and adjusting your trailer brake controller, keep the following in mind:
- Always ensure the trailer wiring harness is securely plugged into your vehicle when using a brake controller.
- Some brake controllers have an "override" or "boost" setting that can be turned off or adjusted for better performance.
- Inertia-based or proportional brake controllers use accelerometers to sense changes in momentum and provide smoother, more precise braking. These are generally more expensive but offer better performance.
- Regularly inspect your trailer brakes, as worn-out components may require manual adjustments or replacements to ensure effective braking.
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Override functions
The override function of an electric trailer brake controller is an important feature that allows you to operate the trailer brakes independently of the vehicle brakes. This function is crucial in situations where you need to avoid or correct trailer sway, providing you with greater control and stability when towing.
To utilise the override function effectively, it is recommended to locate a flat stretch of pavement and reach a speed of around 25 miles per hour. At this speed, you can then pull the manual override lever on the controller to its maximum setting without applying the service brakes of the tow vehicle. This action sends an electric current to the trailer brakes, activating them independently.
If the trailer brakes lock up, release the override lever and reduce the power level. Repeat this process until the brakes no longer lock. Conversely, if the trailer does not respond with a lock, you will need to increase the power level until you achieve the desired braking response. Fine-tuning the settings through this trial-and-error method ensures that your trailer brakes are optimally adjusted.
Additionally, it is important to consider the type of brake controller you have, as this will impact the override function. Time-delay or time-based brake controllers operate by applying an increasing amount of power over a fixed time when the brake pedal is pressed. On the other hand, proportional or inertia-based brake controllers use an accelerometer to sense changes in momentum and apply power proportionally. These controllers provide smoother stops, especially when towing on hills. Understanding the characteristics of your brake controller will help you effectively utilise the override function and make any necessary adjustments.
By following these steps and considerations, you can confidently use the override function of your electric trailer brake controller to enhance your towing experience and ensure the safety of your vehicle and trailer.
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Frequently asked questions
There are two common ways of applying the trailer brakes with an electric brake controller: User-Controlled and Proportional (or inertia sensing). In the User-Controlled method, the user adjusts the braking force via an interface with the controller. In the Proportional mode, accelerometers are used to provide great accuracy of braking measurement across a range of conditions to give optimum braking in response to how hard the vehicle is braking.
The ideal setting for an electric trailer brake controller is when the trailer and car feel to be braking as a system together, without the trailer pushing or pulling the car. The controller should be within reach and visible within the peripheral vision of the driver.
The gain setting depends on the load. One way to set the gain is to put the vehicle in gear on a level ground and slowly move the trailer brake slide so it's fully shut at a speed of 1-5 mph. If the stopping is smooth, the gain is set right. If it feels too slow or too fast, adjust as needed.
If you are installing new electric trailer brakes, you will need to break them in. Drive the trailer to an open area and get up to around 40 mph. Apply the manual override on your brake controller and ensure the controller is set high enough to fully engage the trailer brakes. Do not hit the brake pedal and slow down only using the trailer brakes. Repeat this process about 20 to 30 times.
