Otis Singleton
Servicing the electric brakes on a trailer is an important maintenance task that can help ensure safe and reliable braking performance. The process involves several steps, including raising the trailer, removing the wheel, cleaning and adjusting brake components, and properly reconnecting wires. It is important to identify the type of brake assembly and follow safety guidelines to prevent issues such as spontaneous brake actuation or failure. Regular servicing and adjustment of electric trailer brakes can help maintain optimal performance and prevent premature brake wear or failure.
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What You'll Learn
Identifying electric trailer brakes
Servicing electric trailer brakes is an important aspect of trailer maintenance. Here are some detailed steps to identify electric trailer brakes and perform basic troubleshooting:
Electric trailer brakes are an essential component of trailer systems, and they work in conjunction with the trailer's brake controller. The brake controller is linked to the trailer's brake magnet(s) and is responsible for sending the required electrical current to activate the brakes.
Testing Electric Trailer Brakes
Before embarking on a journey with your trailer, it is crucial to perform a thorough inspection and test of the electric trailer brakes to ensure they are in proper working condition. Here are the steps to identify and test these brakes:
- Visual Inspection: Start by visually inspecting the trailer's brake components, including the brake controller, wiring, and brake magnets. Ensure that all connections are secure and free from damage or corrosion.
- Multimeter Testing: Use a multimeter to test the electrical circuit of the trailer brakes. Set the multimeter to the Ohms (Ω) setting. Connect the negative probe to one of the brake magnet wires, and connect the positive probe to the other magnet wire. Take note of the multimeter's reading, which should be within the specified resistance range for your particular brake magnet size. If the reading is outside the expected range, it indicates a problem with the brakes.
- Brake Controller Test: Check the trailer brake controller by activating the brakes through the pedal or electric control panel. Ensure that the controller is functioning properly and sending the correct current to the brake magnets. You can use a multimeter to test the current between the brake controller and the brake magnet.
- Brake Operation: With the trailer connected to the tow vehicle, manually operate the electric brake controller while attempting to pull the trailer forward. You should feel the trailer brakes engaging and resisting movement.
- Breakaway Brake System: If your trailer is equipped with a breakaway brake system, ensure that the battery is fully charged before use. Test the system by removing the pull pin from the switch and attempting to pull the trailer forward. The brakes should engage and prevent the trailer from moving.
By following these steps, you can effectively identify and test electric trailer brakes, ensuring they are in proper working condition before towing. Regular maintenance and troubleshooting of electric trailer brakes are crucial for safe trailer operation and can help prevent potential accidents or failures.
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Adjusting the brakes
First, it's important to understand the components and their functions. The Adjuster is located below the magnet and should be turnable, with constant pressure from the Adjuster spring. A maxed-out Adjuster may indicate the need for new shoes and linings. Common signs of worn or weak springs are heat, brake drag, or unusual odours. Hold Down Springs are crucial for keeping your brake linings aligned, centred, and mounted securely. Irregular wear on the linings can often be corrected by properly adjusting the brakes and checking the return springs.
To adjust the brakes manually, start by turning the Adjuster until the wheel can no longer turn. Then, slightly adjust it back until the wheel spins freely. A correctly adjusted brake will have a slight constant drag on the shoes.
If you have self-adjusting brakes, they should automatically adjust to compensate for lining and drum wear. However, even self-adjusting brakes may need manual intervention if key components begin to wear. Refer to your OPERATION MAINTENANCE SERVICE MANUAL for specific instructions on adjusting your brakes.
Additionally, ensure that your trailer's connector has been replaced with a 7-way connector, which includes a circuit for electric brakes. This is crucial for powering the brakes.
Finally, be aware that after replacing brake components like shoes and magnets, you may experience decreased braking performance until the components have worn into the drum, a process known as the burnishing process. This may require numerous stops to restore normal braking performance.
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Replacing brake shoes and magnets
To replace the brake shoes and magnets on your electric trailer brakes, follow these steps:
First, you need to inspect the brake controller, which is the mechanical heart of the trailer's braking system. Check the wire conditions for any signs of damage, such as fraying, bumps, tears, or scoring. Ensure that the brake controller contains its schematic or general wiring diagram. This will be important when it's time to wire the trailer according to its specifications.
Next, elevate the trailer and place the axle on a sturdy jack stand. Remove the wheels using a tire iron. If you don't have an impact tool, loosen the lug nuts with a hand tool, and use penetrating oil or heat to loosen any stubborn hardware. Once the wheels are removed, use a chisel and hammer or large slip-jaw pliers to remove the metal grease cap from the hub. The grease cap usually gets deformed during this process, so it's recommended to replace it.
Now, you can remove the brake drum/wheel hub to access the brake components. Remove the cotter pin or keeper retaining the axle nut, then remove the nut, washer, and outer bearing, keeping track of their order and orientation for reassembly. Pull the drum/wheel hub towards you to remove it.
With the brake components exposed, you can now replace the brake shoes and magnets. Clean any rust or debris from the backing plate flange using an air-powered wire wheel or a wire brush. Set the new backing plate on the axle with the electro-magnet at the six o'clock position, ensuring that the left and right plates are installed on their corresponding sides. The brake shoes should be pushed against the inside of the brake drum/wheel hub when the magnet is energized and pulls on the actuating arm. Tighten the mounting nuts to secure the backing plate in place.
Now, you can connect the wires for the electro-magnet to the trailer's wire harness. Solder the wires together or use butt connectors for a secure connection. Use heat shrink tubes or electrical tape to seal the connection and protect it from the weather. Reinstall the loom over the wires and secure them to the torsion arm with a zip tie.
Finally, blast the new drum/wheel hub with brake cleaner and wipe it down to remove any manufacturing oil or corrosion. Set the hub on a work surface with the opening facing up, and install a new bearing with the tapered end pointing towards the work surface. Use a seal driver or a socket to press a new seal into the hub. Reinstall the outer drum and bearing components in reverse order, including the hub, outer wheel bearing, bearing washers, retaining spindle nut, cotter pin, and grease cap. Torque the lug nuts to their designated factory specs using a torque wrench.
Remember to consult a professional mechanic or a detailed step-by-step guide if you need further assistance or encounter any issues during the replacement process.
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Wiring the brakes
Firstly, you'll need to run wiring from the front of your trailer to the trailer brakes to supply them with electricity. This will require a 10-gauge wire with blue insulation. The wire should be routed close to the bottom of the trailer, secured with zip ties and hangers, ensuring it doesn't hang down where it could get damaged.
Each brake assembly will have two wires protruding from the back. One of these wires is for the ground connection, and the other will receive power. It doesn't matter which wire you use for which purpose. Connect the power wire to the non-grounded wire on one of the brakes, then run another wire from this brake to the brake on the other side of the axle. Repeat this process for any additional brakes.
To connect the wires, you can use butt or quick-splice connectors. For the best connection, solder the wires together, or use heat shrink tubes for a weather-tight seal. If you don't have these, electrical tape can also be used to seal the connections and keep water out.
Finally, you'll need to replace the connector at the front of your trailer with a 7-way connector, which includes a circuit to carry power to the brakes. This will ensure that the trailer's brakes are applied if it becomes uncoupled from the tow vehicle.
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Parts needed to add electric brakes
Servicing electric brakes on a trailer requires a variety of parts, depending on the specific setup and requirements of the trailer. Here is a list of common parts needed to add or service electric brakes on a trailer:
Brake mounting flange
The trailer's axle must have a brake mounting flange attached behind the existing hub assembly on each side. Most axles have these as standard, but if your axle does not, you have two options: replace the axle with one that has brake flanges welded in place, or purchase brake flanges and hire a qualified welder to weld them to the existing axle.
Backing plate
The backing plate is a critical component of the braking system. It is directional, so ensure that the left and right plates are installed on their corresponding sides of the trailer. The backing plate should be mounted square and plumb on the axle, with the electro-magnet at the six o'clock position.
Wiring and connectors
Proper wiring is essential for the functioning of electric brakes. You will need wires to connect the electro-magnet to the trailer's wire harness. Solder or use butt connectors for a secure connection, and then seal with heat shrink tubes or electrical tape. You may also need to install a new connector, such as upgrading from a 4-pole to a 7-pole connector.
Brake controller
A brake controller is necessary to operate the electric brakes effectively. The Curt Echo Wireless brake controller is a popular option that does not require wiring.
Breakaway kit
A breakaway kit is essential for safety. These kits apply the trailer's brakes if the trailer becomes uncoupled from the tow vehicle. They typically include a battery, wiring, and sometimes a built-in charger. Ensure the breakaway kit is suitable for the number of axles and brake systems on your trailer.
It is important to consult a professional or a mechanic with experience in trailer brakes to ensure you have the correct parts for your specific trailer and braking system.
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Frequently asked questions
Servicing electric brakes on a trailer involves several steps, including:
- Raising the trailer and removing the wheel
- Cleaning the flange and installing a new backing plate
- Connecting wires to the trailer's wire harness
- Adjusting the brakes
You will need a variety of tools, including an impact wrench, a chisel and hammer, slip-jaw pliers, a wrench or ratchet, and soldering equipment or butt connectors. You may also need an air-powered wire wheel or wire brush, and a voltmeter and ammeter for troubleshooting.
Some common issues include worn or weak springs, which can cause heat, brake drag, or odour. Additionally, ensure that the brake mounting flange is attached to the axle, as the absence of this component may cause spontaneous and unexpected actuation of the brakes.
