Otis Singleton
Electric over hydraulic brakes combines the control of electric braking systems with the stopping power of hydraulic brakes. They are a robust option for trailers used in demanding conditions, offering superior performance for heavy-duty use. This system is more expensive upfront but can result in substantial long-term savings due to reduced maintenance costs. Before towing, it is essential to test the brakes to ensure safety and compliance with regulations. This involves checking the brake controller, performing a road test, and inspecting the brake components for any issues, such as strange noises, oil leaks, or deformation. Proper maintenance and servicing are crucial to avoid brake failure and potential accidents.
| Characteristics | Values |
|---|---|
| Type | Electric-over-hydraulic brakes |
| Usage | Trailers, heavy-duty use, hotshot trucking industry |
| Benefits | Stronger stopping power, fewer electrical connections at the hubs, reduced maintenance costs, improved durability, robust option for demanding conditions |
| Testing | Check the brake controller while trying to pull the wheelhouse, operate the electric brake controller while towing under 5 mph, ensure the wheelhouse brakes are functioning |
| Maintenance | Easy to inspect and replace calipers and brake pads, simple to bleed the system if air gets into the lines, store the battery indoors and charge every three months if not in use |
| Common Problems | Strange noises, improper trips, air mixing, oil leaks, overheating, deformation of discs, oil-related issues, small gaps and tightness |
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What You'll Learn
Check the breakaway brake system
Electric over hydraulic brakes are a combination of the control of electric braking systems and the stopping power of hydraulic brakes. They are a robust option for trailers used in demanding conditions. This system uses hydraulic brake fluid, similar to what is found in cars, enhancing the overall braking efficiency.
The breakaway brake system is an essential safety feature for any trailer or wheelhouse. It is the last line of defence against a runaway trailer/wheelhouse and potential injury or damage. The breakaway kit includes a battery, a switch with a pull pin and lanyard, and a breakaway brake controller. The breakaway switch is mounted to the trailer frame and has a cable that connects to the vehicle's frame. If the trailer disconnects, the cable pulls a pin out of the switch, activating the trailer brakes.
To test the breakaway brake system, follow these steps:
- Consult the owner's guide or manual for your specific make and model of the trailer/wheelhouse. Different manufacturers may have different instructions and procedures for testing the breakaway brake system.
- Inspect the battery: Ensure that the breakaway battery is fully charged before conducting the test. Most wheelhouses are set up to charge the battery from the tow vehicle. If your electric system does not provide this charge, you must periodically charge the battery with a commercial battery charger.
- Remove the pull pin: As per the instructions provided by Yetti Outdoors, remove the pull pin from the switch.
- Attempt to pull the trailer/wheelhouse forward: With the pull pin removed, try to pull the trailer or wheelhouse forward manually. You should feel resistance to towing, but the wheels do not need to be locked. This indicates that the breakaway brake system is functioning correctly.
- Check the breakaway switch: Ensure that the breakaway switch is securely mounted and safely positioned. The switch should be safe from dragging or debris, and the wiring should reach the trailer hitch. Disconnection of the hitch triggers the switch and the entire breakaway brake system.
- Regular maintenance: Store the battery indoors and charge it every three months if the wheelhouse is not in use for extended periods. Replace the breakaway brake battery as per the manufacturer's recommended intervals.
Remember, never tow your trailer or wheelhouse if the breakaway brake system is not functioning properly. Always have it serviced or repaired before towing to ensure your safety and compliance with state regulations.
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Test the battery
Testing the battery of electric over hydraulic brakes is a crucial aspect of ensuring the overall functionality and safety of the braking system. Here is a detailed guide on how to test the battery:
Understanding the System
Electric over hydraulic brakes combine the control of electric braking systems with the stopping power of hydraulic mechanisms. This integration enhances braking efficiency and makes them suitable for heavy-duty use. It's important to consult the instructions provided by the brake manufacturer for specific details about your system.
Battery Location
The battery for the breakaway brake system is typically found near the breakaway switch in a hydraulic wheelhouse. If your wheelhouse utilises the hoist battery to power the breakaway brakes, then the breakaway brake battery may not be present.
Charging the Battery
Before conducting any tests, ensure that the breakaway brake battery is fully charged. If your tow vehicle does not charge the battery, use a commercial battery charger periodically to maintain the battery's charge. It is imperative to charge the battery before towing to ensure optimal performance.
Testing the Battery
To test the battery, follow these steps:
- Remove the pull pin from the switch.
- Attempt to pull the wheelhouse forward manually.
- Observe whether the wheelhouse resists being towed.
During this test, you should feel resistance, indicating that the battery is functioning correctly. However, the wheels do not need to be locked. If the battery is not functioning, it must be recharged or replaced before towing.
Additionally, when towing at less than 5 mph, manually operate the electric brake controller in the tow vehicle. You should feel the operation of the wheelhouse brakes. If they are not functioning, have the brake system evaluated and take corrective action before using the wheelhouse.
Storage and Maintenance
Proper storage and maintenance of the battery are essential. If the wheelhouse is not in use for extended periods, store the battery indoors and charge it periodically. Regularly inspect the battery and follow the manufacturer's recommendations for replacement intervals to ensure optimal performance and safety.
Safety Precautions
Never tow the wheelhouse if the breakaway brake system is not functioning properly. An ineffective breakaway brake system can lead to dangerous situations, including runaway wheelhouses. Always service or repair the brake system before towing if any issues are identified.
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Inspect calipers and brake pads
Inspecting calipers and brake pads is a crucial aspect of brake maintenance. Here is a detailed guide on how to perform this inspection:
Locating the Brake Pads and Calipers:
First, locate the brake pads and calipers. In many vehicles, you can find them by looking through the wheel spokes at the metal disc or rotor. The brake pads are the flat objects pressing against both sides of the rotor, and the calipers are the clamp-like devices above each rotor.
Inspecting the Brake Pads:
To get a better view of the brake pads and calipers, you may need to elevate your vehicle and remove the wheel. Place your jack under the vehicle frame next to the tire you want to remove, ensuring your car is on level ground. Elevate the vehicle, remove the lug nuts, and take off the wheel.
Once the wheel is removed, carefully inspect the brake pads for excessive wear and tear. Look for cracks, grooves, or uneven wear. Use a ruler or gauge to measure the pad thickness; new pads are typically around 12mm thick, and it's recommended to replace them when they reach approximately 4mm or 20% pad life remaining. Also, check for fluid leaks near the calipers, as these may indicate hydraulic issues.
Inspecting the Calipers:
After inspecting the brake pads, focus on the calipers. If the outer brake pad is in good condition but the inner pad is worn, the caliper piston could be sticking and not releasing properly. This results in constant pressure on the inner pad, leading to premature wear. Check for any signs of dragging or sticking, and ensure the calipers are functioning smoothly.
Replacing the Brake Pads:
If the brake pads are excessively worn or damaged, replace them with new ones. Brake pads should typically be replaced when approximately 1/4" to 3/16" of friction material remains on the steel backing plate. It is recommended to replace the entire set of brake pads on an axle for balanced braking if one pad is thinner than the others.
Post-Inspection Procedures:
After completing the inspection and any necessary replacements, reinstall the wheel, tighten the lug nuts, and lower the vehicle. Pump the brakes until the pedal feels firm before driving. Consult your vehicle's owner's manual for model-specific details, and always seek professional advice if you have any doubts or concerns.
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Check for leaks
Checking for leaks in electric over hydraulic brakes is an important safety measure. A properly set-up hydraulic brake system should not leak fluid over time, but it is still important to check for leaks as part of regular vehicle maintenance.
To test for leaks, start with the vehicle stopped on a level surface to ensure safety and accuracy. Next, pump the brake pedal three times to build pressure in the hydraulic system. Then, apply firm pressure to the brake pedal and hold it for five seconds. This allows you to assess if the pedal holds its position under consistent pressure. After maintaining pressure, observe the brake pedal closely. If the pedal slowly sinks towards the floor, this is an indication of a possible leak in the hydraulic system.
If you suspect a leak, check the brake fluid levels and inspect the brake lines for leaks. If there is a leak, it is important to get it fixed before driving. Federal and state laws prohibit operating an unsafe vehicle.
In addition to checking for leaks, it is important to inspect the brakes for other issues. For example, debris on the aluminium piston seal and piston surface can cause the piston to wear and leak oil. It is also important to check the disc for deformation and deflection, as well as ensure that the wheelset is correctly installed.
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Compare to traditional electric brakes
Electric over hydraulic brakes combines the control of electric braking systems with the stopping power of hydraulic brakes. This makes them a more robust option for trailers frequently used in demanding conditions. This system eliminates many of the common issues associated with traditional electric brakes, making them a superior choice for heavy-duty use.
Electric brakes have been the go-to option for trailers for years due to their cost-effectiveness. However, in the hotshot trucking industry, electric brakes often lead to problems due to their design and durability under extensive use. Electric brakes rely on an electromagnet to activate the brake pads, which can wear down over time due to constant movement and road debris. This can lead to faults and the need for replacements, resulting in fines and safety issues on the road.
In contrast, electric over hydraulic brakes offer stronger stopping power and enhanced braking efficiency. They use hydraulic brake fluid, similar to cars, and provide smoother brake engagement. The electrical connections stop at the brake booster, reducing the risk of electrical faults at the hubs. Additionally, the separate hydraulic fluid reservoir in electric over hydraulic brakes prevents leaks from reaching the circuit board, enhancing the overall reliability of the braking system.
While electric over hydraulic brakes may be more expensive upfront, they can provide substantial long-term savings due to reduced maintenance costs. The calipers and brake pads are easily accessible and visible, making maintenance straightforward. This system also provides proportional braking control, ensuring balanced braking and enhancing overall driving safety.
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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. This makes them a robust option for trailers used in demanding conditions.
Remove the pull pin from the switch and attempt to pull the wheelhouse forward. If your wheelhouse uses electric brakes, your tow vehicle will have an electric brake controller that sends power to the wheelhouse brakes. Before towing on the road, you must operate the brake controller while trying to pull the wheelhouse to confirm the brakes are working.
Electric-over-hydraulic brakes are more expensive upfront than regular electric brakes. However, they have fewer electrical connections at the hubs, minimising issues caused by debris and corrosion. They also have stronger stopping power and are more durable under constant commercial use.
Common issues with hydraulic disc brakes include strange noises, improper trips, air mixing, oil leaks, and overheating. Other issues include oil-related problems such as poor rebound of the lining, oil leaks from deformed washers or debris on the piston seal, and full pressure in the oil disc due to overfilled oil or absorbed water vapour.
