Trystan Casey
Electric over hydraulic brakes are a type of braking system that combines the control of electric brakes with the stopping power of hydraulic brakes. They are activated when the tow vehicle brakes are applied, with the trailer's brakes responding almost instantly. This system is considered an upgrade from standard electric brakes, which were developed in the 1940s and are more prone to wear and tear, and hydraulic brakes, which take longer to apply. Electric over hydraulic brakes are especially useful for trailers that are frequently used in demanding conditions or heavy-duty use, as they provide stronger stopping power and minimise issues caused by debris and corrosion. To service this type of braking system, it is important to first identify and gather the necessary parts, which may include a brake controller, an electric over hydraulic brake actuator, hydraulic disc brakes, wiring, pressure lines, and a brake line kit. The process involves jacking up the trailer, removing the wheels, and accessing the brake assembly. The electric brake drums and backing plates are then removed, and new components such as caliper brackets, bearings, seals, and brake calipers are installed. The electric over hydraulic actuator is mounted on the trailer, wired according to the manufacturer's instructions, and connected to the calipers using steel brake line tubing. Finally, the wheels are reinstalled, the brakes are bled, and the system is tested.
| Characteristics | Values |
|---|---|
| Type | Electric over hydraulic brakes |
| Application | Boat trailers, trucks, hotshot trucking industry |
| Benefits | Superior to electric brakes, stronger stopping power, combines control of electric braking systems with stopping power of hydraulic brakes, fewer electrical connections at the hubs, consistent braking, no adjustment needed, full force to all wheel positions, improved safety, reduced maintenance costs |
| Drawbacks | More expensive upfront, not designed to be submersible, compatibility issues with some vehicles, prone to faults and malfunctions |
| Installation | Wire the tow vehicle for electric brakes, install hydraulic brake lines and brakes on the trailer, mount the actuator on the trailer, connect actuator to calipers with steel brake line tubing, install high-pressure lines between the brake actuator and disc brakes |
| Maintenance | Easy to inspect and replace calipers and brake pads, simple to bleed the system if air gets into the lines |
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What You'll Learn
Electric over hydraulic brakes vs. regular electric brakes
Electric over hydraulic brakes are a newer technology that offers several advantages over regular electric brakes. One of the most significant benefits is the increased braking pressure they can generate, with over 1,000 lbs. of braking pressure compared to 400-500 lbs. on electric brake systems. This additional pressure results in stronger braking force, making electric over hydraulic brakes ideal for heavy loads and giving them superior stopping power.
Another advantage of electric over hydraulic brakes is that they do not require adjustment, unlike electric brake systems. Electric brakes rely on an electromagnet to activate the brake pads, which can wear down over time due to constant movement and road debris, leading to a decrease in braking power. In contrast, electric over hydraulic brakes generate equal and full force to all wheel positions, resulting in consistent braking throughout the life of the disc brake pads.
The design of electric over hydraulic brakes also offers improved control when towing heavy loads. This type of braking system combines the control of electric braking with the stopping power of hydraulic brakes, resulting in a more robust option for trailers used in demanding conditions. The system provides proportional braking, ensuring that the truck and trailer stop together evenly, rather than one stopping before the other, which can be an issue with electric brakes.
In terms of maintenance, electric over hydraulic brakes may also offer some benefits. On axles equipped with disc brakes, the calipers and brake pads are visible and easily accessible, making maintenance and replacement straightforward. Additionally, bleeding the system if air gets into the lines is a simple process. However, it is important to note that electric over hydraulic brakes are generally more expensive upfront than regular electric brakes, which may be a deciding factor for some trailer owners.
Overall, electric over hydraulic brakes offer improved performance, reliability, and safety compared to regular electric brakes, making them a superior choice for heavy-duty and extensive use. However, the higher upfront cost and potential compatibility issues with certain vehicles are considerations that may favour the more commonly used electric brake systems.
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How to wire an electric over hydraulic brake system
Electric-over-hydraulic brakes combine the control of electric braking systems with the stopping power of hydraulic brakes. They are a robust option for trailers used in demanding conditions.
To wire an electric-over-hydraulic brake system, you will need to wire the tow vehicle for electric brakes and install hydraulic brake lines and brakes on the trailer. The brake controller is wired into the truck, and the brake actuator is wired into the connector on the trailer where the truck plugs into it.
Firstly, determine where to mount the electric-over-hydraulic actuator. Considerations include the physical size of the actuator and whether it is weatherproof. A weatherproof actuator allows the actuator to be mounted anywhere. The actuator is usually mounted on the trailer and receives electric signals from the tow vehicle's brake controller, applying pressure to the trailer's hydraulic brake lines.
Next, install the actuator on the trailer and wire it according to the manufacturer's recommendations. Steel brake line tubing is used to run from the actuator to the calipers. Once everything is connected, bleed the brakes and test the system before installing the wheels back onto the trailer.
Finally, connect the wiring. Refer to the instructions for your brake controller and brake away system, as they need to be connected in a specific way to function properly. Cut, strip, crimp, shrink, and connect each wire and connection. You may also need to connect the harness to the truck and adjust the length.
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The benefits of electric over hydraulic brakes
Electric over hydraulic brakes have several advantages over other braking systems. Firstly, they offer superior stopping power compared to regular electric brakes. This is because they generate over 1,000 lbs. of braking pressure, whereas electric brake systems typically produce only 400-500 lbs. of pressure. This extra stopping power can be crucial, especially when towing heavy loads.
Another benefit of electric over hydraulic brakes is their consistency and reliability. Unlike electric brake systems, hydraulic systems do not need adjustment and provide equal and full force to all wheel positions, resulting in consistent braking. This is because the system uses hydraulic fluid to directly engage the brakes, ensuring smooth and even braking. Electric over hydraulic brakes are also less prone to faults and malfunctions, reducing the risk of safety issues and potential fines due to Department of Transportation (DOT) violations.
Additionally, electric over hydraulic brakes provide enhanced safety and peace of mind, especially for long-distance towing. The system uses both the tow vehicle and trailer brakes, ensuring even stopping without one component stopping the other. The cab controller is another essential feature, allowing drivers to adjust the sensitivity of the trailer brakes according to their preferences and external conditions.
While electric over hydraulic brakes have a higher upfront cost, they offer better performance and reliability, resulting in lower long-term costs. This makes them a worthy investment for those in the trucking industry or anyone using trailers extensively. The system's compatibility with different brake types (disc or drum) and its ease of maintenance further add to its advantages.
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Electric over hydraulic brakes installation
Electric over hydraulic brakes is an option for boat trailers. This braking system is activated whenever the tow vehicle brakes are applied and the trailer surges forward. The system is superior to its electric counterparts, generating over 1,000 lbs of braking pressure compared to 400-500 lbs on electric brake systems.
There are three main parts to electric over hydraulic brake installation: the brake controller in the truck, the electric over hydraulic brake actuator on the trailer, and the hydraulic disc brakes on the wheels of the trailer. The first step is to jack up the trailer and remove the wheels to access the brake assembly. Then, the electric brake drums and backing plates need to be removed, and the caliper bracket installed on the axles brake flange. The new bearings packed with grease are then installed, along with the seals, into the integrated hub rotor, which is then installed on the spindle. The brake calipers can then be mounted onto the caliper bracket.
The next step is to determine where to mount the electric over hydraulic actuator. Considerations include the physical size of the actuator and whether it is weatherproof. A weatherproof actuator, such as the Brakerite EHB, can be mounted anywhere. The actuator is then installed on the trailer and wired per the manufacturer's recommendation. Steel brake line tubing is then used to run from the actuator to the calipers. Steel tubing is preferred over rubber due to the high pressures generated by electric over hydraulic actuators.
Finally, the brakes are bled and the system is tested. The wheels are then installed back onto the trailer. It is important to note that the actuator on an electric over hydraulic system should not be submerged in water, although it is built to handle heavy weather while on the road.
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Maintenance and servicing of electric over hydraulic brakes
Electric over hydraulic brakes offers a robust braking system for trailers used in demanding conditions. This system combines the control of electric braking mechanisms with the stopping power of hydraulic brakes.
Electric over hydraulic brakes components:
The system consists of three main components: a brake controller for the truck, an electric over hydraulic brake actuator for the trailer, and hydraulic disc brakes for the trailer wheels. The brake controller is wired into the truck, and the brake actuator is wired into the trailer's connector. The actuator is placed as far up the front of the trailer as possible to avoid getting wet. The actuator should not be submerged, but it is built to withstand heavy weather.
Installation and compatibility:
Before installing the system, ensure that all parts are shipped and compatible with the trailer. Electric over hydraulic brakes may encounter compatibility issues with certain vehicles, such as some GMC trucks, resulting in fault messages. Consult a dealer to ensure compatibility.
Maintenance:
Electric over hydraulic brakes require less maintenance than electric brakes due to fewer moving parts. The calipers and brake pads are easily accessible and can be inspected and replaced if necessary. Bleeding the system is simple if air gets into the lines.
Upfront cost and long-term savings:
While electric over hydraulic brakes have a higher upfront cost, they offer long-term savings by reducing maintenance costs. The system's robust design makes it ideal for heavy-duty use, minimising issues associated with traditional electric brakes.
Safety and performance:
Federal law requires a breakaway kit, including a battery, to activate the trailer brakes in the event of separation from the tow vehicle. Electric over hydraulic brakes provide stronger stopping power than electric brakes, enhancing safety and reliability.
Actuator considerations:
When mounting the actuator, consider its physical size and whether it is weatherproof. A weatherproof actuator, such as the Brakerite EHB, can be mounted anywhere. Avoid power-washing the actuator, as it is not designed to be submersible, and light rinsing is recommended.
The above information provides an overview of the maintenance and servicing considerations for electric over hydraulic brakes, ensuring optimal performance, safety, and compliance with regulations.
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Frequently asked questions
Electric-over-hydraulic brakes combine the control of electric braking systems with the stopping power of hydraulic brakes. They are a robust option for trailers used in demanding conditions.
Electric-over-hydraulic brakes offer a smoother braking sensation than electric drum brakes. They also eliminate many of the common issues associated with traditional electric brakes, such as faults and malfunctions that can lead to safety issues and fines.
To install electric-over-hydraulic brakes, you need to wire the tow vehicle for electric brakes and install hydraulic brake lines and brakes on the trailer. You will also need a brake controller for the truck, an electric-over-hydraulic brake actuator for the trailer, and hydraulic disc brakes for the trailer's wheels.
The key components of an electric-over-hydraulic brake system are the brake controller, the electric-over-hydraulic brake actuator, and the hydraulic disc brakes. These components require wiring and pressure lines to connect them.
When choosing electric-over-hydraulic brakes for your trailer, consider the size and weight of the trailer, the type of trailer (e.g. boat trailer, hotshot trucking trailer), and the frequency of use. Additionally, ensure compatibility with your tow vehicle to avoid issues with the brake controller and voltage sensitivity.
