Umair Gaines
Electric brakes are a legal requirement for caravans over 750kg and are also a safety feature. Caravan owners should be aware of the many points of failure in the braking system, which can go unnoticed until an emergency situation arises. To avoid this, there are several checks that can be performed on the caravan's electric brakes. These include checking the brake magnet, the trailer brake wiring, and the current from the electric brake controller. In addition, the wires that provide power to the electric brakes are vulnerable to damage and should be inspected for any signs of wear and tear.
| Characteristics | Values |
|---|---|
| Caravan brakes check | Check for wiring faults, especially if the wires are joined with BP connectors |
| Check the brake magnet for wear and tear, and test with a meter | |
| Check the handbrake by pulling the lever; if you have to pull it beyond 3/4 position before the brakes apply, the cable needs adjusting | |
| Check the emergency breakaway system | |
| Check the wires at the back of the wheel hub for damage | |
| Check the zip ties holding the wires in place | |
| Testing electric brakes | Use a multimeter to test trailer brake wiring between the brake controller and the brake magnet |
| Measure the amperage across the blue wire | |
| Measure resistance by setting the multimeter to Ohms | |
| Check for internal shorts in the brake magnet | |
| Check for wiring shorts in the 7-way plug | |
| Disconnect the 6-way plug between the chassis and the tongue/drawbar to isolate the fault | |
| Check for a direct short from the blue wire to earth | |
| Check for a short circuit on the electric brake output wire |
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What You'll Learn
Check the brake magnet for wear and tear
When checking the brake magnet for wear and tear, you should first identify the type of brake magnet you have. There are two main types: standard brake magnets and off-road brake magnets. A standard brake magnet has a retaining clip to hold the magnet in position on the arm of the backing plate, while an off-road brake magnet has a plastic centre to reduce wear and tear from the magnet arm vibrating on rough terrain. It uses a rubber band to hold the magnet in position.
Once you have identified the type of brake magnet, you can proceed to check for wear and tear. Pull a brake drum and inspect the magnets that ride against the armature surface of your brake drum. Look for any visible signs of wear and tear on the magnets, such as exposed windings or copper wiring. If you see any windings or copper wiring through the friction surface or face of the magnet, it indicates abnormal wear, and the magnets will need to be replaced.
Additionally, you can check the four small holes on the face of the magnet, known as "wear indicators". If you cannot see all four wear indicator holes, or if the centre of the magnet hole has worn out, then the magnet needs to be replaced. It is important to always bed new magnets before regular use. Once the wear indicators are no longer visible, the copper underneath may become exposed, potentially causing an open electric circuit and rendering your brakes useless.
To further diagnose potential issues with the brake magnet, you can use a multimeter to test for the proper voltage and current. Set your multimeter to Ohms (Ω) to measure resistance, and place the probes on the brake magnet wires. The expected reading for a 10-inch brake drum is between 3.8 and 4.0 ohms. If the reading is outside this range, the magnet may need to be replaced. You can also use the multimeter to test the trailer brake wiring between the brake controller and the brake magnet to identify any internal shorts.
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Test the trailer brake wiring
Testing the trailer brake wiring is essential to ensure the safety of your caravan. Electric brake wiring faults can significantly impact performance and put your vehicle at risk.
Firstly, you should check the magnets for any signs of wear or exposed windings. Magnets can go bad without showing visible signs of wear, so it's important to test them with a meter. Place the brake magnet on the negative battery post and use a multimeter to test the trailer brake wiring between the brake controller and the brake magnet. If you get any ampere reading, there is an internal short, and the magnet needs to be replaced.
To measure resistance, set your multimeter to Ohms (Ω). Place the black probe on any of the brake magnet wires and the red probe on the other wire. Check the readings on your multimeter against the specifications for your brake drum size. If the reading is outside the expected range, the magnet is faulty and needs replacing.
With your car turned on, connect one probe to the blue wire from your connector plug and the other probe to one of your brake magnet wires. Activate the brakes through the pedal or control panel and measure the current. Compare this to the recommended current for your magnet wires. If the current is above or below the specification, the controller or wires may need to be changed.
It is important to note that some controllers require resistance (a load) to function, so the directions for determining amperage may not apply to all brake controllers.
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Measure the current from the connector to the brake wires
To measure the current from the connector to the brake wires, you will need to use a multimeter. The multimeter should be set to Ohms, which is usually represented by the Omega symbol (Ω).
Firstly, connect one probe to the blue wire coming from your connector plug. Then, connect the other probe to one of your brake magnet wires. It does not matter which brake magnet wire you choose because there is no polarity between your brake magnet wires.
With your car turned on, you can now activate the brakes through the pedal or electric control panel. You can ask a friend to help with this step. Now, you can measure the amount of current coming from the connector to the brake wires.
Using the specifications mentioned above, determine whether you are getting the right amount of current. If the current goes above or below your recommended specification, then the controller or wires may be faulty and need to be replaced.
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Check the handbrake
Checking the handbrake on your caravan is a simple process, but it does require periodic adjustment. Firstly, you should inspect the handbrake lever. If you have to pull the handbrake lever beyond the 3/4 position for the brakes to apply, then the cable tension likely needs adjusting. Adjusting the handbrake cable tension is a simple task. You simply need to undo the locknuts and then turn the adjuster wheel clockwise a few turns until the brakes are tightly applied with the lever raised to around the halfway point. If you are unsure about how to do this, there are plenty of tutorial videos available on YouTube, or you could ask a local mechanic to adjust them for you.
It is important to check the handbrake on your caravan before each trip. Caravan handbrakes are simple devices, but they do require regular maintenance to ensure they are functioning correctly. This will help to keep you safe on the road and reduce the risk of an accident.
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Check the emergency breakaway system
Checking your emergency breakaway system is a crucial aspect of ensuring your caravan's roadworthiness and safety. Here are the steps you should follow:
First, understand the components of the breakaway system. This includes a battery, a switch, and a cable connected to a pin. The battery powers the electric brakes, while the switch activates them in an emergency. The cable is attached to the tow vehicle and, in the event of uncoupling, pulls out the pin from the switch, triggering the system.
Next, inspect the battery. The breakaway system battery must be adequately charged to ensure the electric brakes function correctly. Check the battery's charge level and ensure it is maintained, as a flat battery could render the breakaway system inactive. Consider installing a breakaway battery monitor, which provides a visual and auditory warning if the battery charge falls below a specified level. While this is mandatory for certain states and registrations, it is a valuable safety feature regardless of location.
After that, examine the switch and cable assembly. Verify that the switch is securely attached to the caravan's A-frame and linked to the electric brake circuit. Ensure the cable is properly secured to the tow vehicle. Check that the cable length is appropriate, not too loose or too tight, to guarantee the activation of the breakaway system in an emergency.
Finally, perform a functional test. With the caravan stationary, simulate an uncoupling event by gently pulling the cable to remove the pin from the switch. Observe if the electric brakes engage and the brake lights illuminate. Additionally, inspect the condition of your caravan brakes by checking the friction material on the brake shoes and ensuring the magnets and wiring are in good condition.
Remember, the emergency breakaway system is a vital safety feature for caravans, especially those over 2000 kg, as it helps prevent accidents and ensures the caravan comes to a safe stop if it detaches from the tow vehicle.
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Frequently asked questions
Check the magnets for any signs of wear and tear. Also, inspect the wiring for any damage as these wires are vulnerable to damage caused by stones, water, and general wear and tear.
You can use a multimeter to test the trailer brake wiring between the brake controller and the brake magnet. Place one probe on the blue wire coming from your connector plug and the other probe on one of the brake magnet wires. Measure the amount of current and determine if it is within the recommended specification.
If your controller is not working properly, or the current is not reaching the electromagnets, you may need to change the controller or wires. You can also check for wiring shorts by opening the 7-way plug and disconnecting the 6-way plug between the chassis and tongue/drawbar.
Set your multimeter to Ohms (Ω) and place the probes on any of the brake magnet wires. Check the readings and compare them to the specifications for your brake drum size. If the reading is outside the expected range, the magnet may need to be replaced.
One common issue is the quality of connections. BP connectors are often used, but they are not suitable for mobile vehicles and can cause problems. It is important to consult a professional technician for further advice and to optimize the efficiency of your electric brakes.
