Beatrice Lang
Electric over hydraulic brakes is a braking system that combines the advantages of electric and hydraulic brakes. Electric brakes are generally cheaper, while hydraulic brakes are more durable and less affected by weather conditions. When converting a trailer with surge brakes to electric over hydraulic brakes, you will need to remove the old hydraulic equipment, including the hydraulic actuator, lines, and brake assemblies. You will then need to install a new electric over hydraulic actuator, brake controller, and hydraulic disc brakes on the wheels. This process involves wiring and connecting pressure lines between the components. It is important to ensure that all correct parts are available and that the trailer is securely supported during the conversion process.
Characteristics and Values Table for Changing Hydraulic Brakes to Electric
| Characteristics | Values |
|---|---|
| When to change | When the hydraulic brake system is not working or not working properly |
| When not to change | When the truck is not equipped with a brake controller |
| Benefits of electric brakes | Better braking, less jerky sensation, no need for adjustment, consistent braking |
| Benefits of hydraulic brakes | Less affected by adverse weather conditions, more durable and long-lasting, reduced maintenance needs |
| Tools required | Hydraulic brake kit, electrical insulating and moisture sealing tape, self-locking cable zip ties, assembly tool, utility knife, screwdriver, scissors |
| Steps | Cut off zip ties, remove cable sleeving, slowly pull out brake cables, loosen screw holding brake cable, pull out cable, remove old hydraulic equipment, install new electric brake assemblies |
| Additional considerations | Whether to use disc or drum brakes, whether to use a junction box, whether to use a breakaway kit, whether to replace the drums |
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What You'll Learn
Electric brakes are more expensive but require less maintenance
Electric brakes are generally more expensive than hydraulic brakes. However, they require less maintenance and offer better braking performance. For example, electric scooter riders benefit from powerful braking abilities in both wet and dry conditions. Electric brakes are also lightweight and low-maintenance.
When converting from hydraulic to electric brakes, you will need to decide what to do with the hydraulic actuator on the tongue. You can either weld it up solid or remove it and install a better hitch plate or channel on the tongue for a coupler. Additionally, you will need to add a breakaway battery and switch, and replace the brake assemblies.
For trailers with surge brakes, you will need an electric-over-hydraulic actuator and a brake controller. It is important to choose a compatible brake controller, such as the Tekonsha Prodigy P3 Trailer Brake Controller. You may also need to replace the coupler with a standard one, as the old coupler will no longer need to be actuated.
While electric brakes may be more expensive upfront, they can save money in the long run by reducing maintenance costs. Electric cars, for example, have fewer moving parts and fluids, eliminating the need for routine maintenance such as oil changes, transmission servicing, and air filter replacements. Additionally, regenerative braking in electric vehicles recharges the battery when braking, extending the range and reducing brake wear.
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Remove old hydraulic equipment
To remove the old hydraulic equipment, you will need to first securely lift and support the trailer using properly rated jack stands.
Next, you will need to decide what to do with the hydraulic actuator on the tongue. You can either weld it up solid or remove it and install a better hitch plate or channel on the tongue for a coupler. If you choose to remove it, you will also need to add a breakaway battery and switch.
After that, remove the surge coupler or actuator, all the lines, and the brake assemblies. If you have 10-inch diameter hub and drums, you will need to replace them, but if you have 12-inch hub and drums, you can reuse them as long as they are in good shape.
Finally, you will need to run the brake line that was previously going to the actuating coupler to the electric-over-hydraulic actuator.
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Install a breakaway battery and switch
When changing from hydraulic brakes to electric brakes, it is important to install a breakaway battery and switch. This safety system is required in most states for trailers weighing more than 3,000 lbs. The breakaway kit is designed to bring trailers to a safe stop by activating the electric brakes if the trailer disconnects from the tow vehicle.
To install a breakaway battery and switch, first locate a secure surface on the trailer to mount the breakaway kit battery box. Typically, this is on the inside of one of the trailer frames at the front of the trailer. The breakaway switch should be mounted to the trailer frame and have a cable that connects to the vehicle's frame. The cable can be attached in multiple ways, with the two most common methods being:
- Routing the pin through the safety chain loops on the hitch or bumper, and then through the cable loop.
- Routing the pin through a tow hook, and then through the cable loop.
To test if the breakaway system is working, pull the breakaway cable pin from the switch box using pliers. If the trailer brakes lock up, the breakaway battery is charged and the system is functioning. If the battery is depleted, the system won't work, and the trailer will roll freely.
Remember to periodically remove the battery from the box to charge it or replace it as needed.
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Electric over hydraulic brakes generate over 1,000 lbs of braking pressure
Electric over hydraulic brakes are a superior option for trailers and trucks used in demanding conditions. They offer a robust combination of the control of electric braking systems and the stopping power of hydraulic brakes, making them a robust option for trailers frequently used in demanding conditions. This system also eliminates the common issues associated with traditional electric brakes, making them ideal for heavy-duty use.
Electric brakes, though cost-effective, often lead to problems in the trucking industry due to their design and durability under extensive use. They are prone to wear and tear, faults, and malfunctions, which can result in safety issues and Department of Transportation (DOT) violations.
On the other hand, electric over hydraulic brakes generate over 1,000 lbs of braking pressure, significantly outperforming electric brake systems, which typically manage 400-500 lbs of pressure. The hydraulic systems do not require adjustments and deliver equal and full force to all wheel positions, resulting in consistent braking. This consistency is further enhanced by the use of hydraulic brake fluid, similar to that found in cars, which directly engages the brakes.
To convert from hydraulic surge brakes to an electric over hydraulic system, you will need an electric over hydraulic actuator and a compatible brake controller. The actuator options include the Carlisle HydraStar units, with part # HBA-10 for drum brakes and # HBA16 for disc brakes. For the brake controller, a recommendation is the Tekonsha Prodigy P3 Trailer Brake Controller (# 90195).
Additionally, consider the physical size and weatherproofing of the actuator. A weatherproof option like the Brakerite EHB allows for flexible mounting. After installing the actuator on the trailer, steel brake line tubing is preferred over rubber due to the high pressures generated. The final steps include bleeding the brakes, testing the system, and reinstalling the wheels.
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Ensure safety by disconnecting the battery
When converting hydraulic brakes to electric brakes, it is important to prioritise safety by disconnecting the battery. This is a vital safety measure that can prevent electrical shocks, accidental scooter activation, and potential injuries. Here are some detailed steps to ensure safety during the conversion process:
Firstly, it is crucial to securely lift and support the trailer using properly rated jack stands. This provides stability and ensures the trailer remains immobile during the conversion process.
Next, locate the battery and its cables. Before disconnecting the battery, ensure that you have the appropriate tools and safety equipment. It is recommended to wear protective gloves and goggles to safeguard against any potential hazards.
When disconnecting the battery, always start by disconnecting the grounded side first, which is typically the negative terminal. This is because, if the wrench accidentally touches the car body, disconnecting the positive side first could lead to a short circuit. Make sure to avoid touching any car body parts while handling the wrench to prevent accidental contact.
In some older cars, the positive cable may be connected to the body, so it is important to verify the cable connections before proceeding. Additionally, if the battery shows signs of damage, such as a crushed casing or outgassing, take extra precautions. Cover the battery terminals with plastic cups, double-layer tape, or suitable insulation to prevent sparks and protect against outgassing.
Once the battery is safely disconnected, you can proceed with the conversion, ensuring that the work area is clear and well-organised. Keep the battery in a secure location away from the work area to avoid any accidental reconnections.
By following these steps, you can help ensure a safe and controlled environment for converting hydraulic brakes to electric brakes.
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Frequently asked questions
Electric brakes are more powerful, generating over 1,000 lbs. of braking pressure compared to 400-500 lbs. on hydraulic brake systems. They also don't require adjustment and generate equal and full force to all wheel positions, resulting in consistent braking.
You will need to remove the old hydraulic equipment, including the hydraulic actuator, lines, and brake assemblies. You will then need to install a new electric brake kit, which may include items such as an electric brake controller, an electric-over-hydraulic actuator, and hydraulic disc brakes.
First, ensure the trailer is securely lifted and supported using jack stands. Then, remove the hydraulic coupler or actuator, lines, and brake assemblies. If you have a hydraulic surge brake, you will need to decide what to do with the hydraulic actuator on the tongue, either by welding it solid or removing and replacing it with a better hitch plate or channel for a coupler.
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