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Self-adjusting electric trailer brakes are braking systems used in travel trailers and fifth wheels. They are designed to adjust automatically during every forward stop, providing improved braking distance and safety. These brakes rely on an electromagnet connected to an actuating arm, which is energised by an electric current from the brake controller. When energised, the magnet attracts to the rotating surface of the drum, causing the actuating arm to press the brake shoes against the drum, creating friction and slowing the wheels. Self-adjusting trailer brakes offer advantages over manual brakes, which require periodic manual adjustments and can be prone to reduced performance over time.
| Characteristics | Values |
|---|---|
| Types | Forward Self Adjusting (FSA) and Manual Adjusting |
| Adjustment | Self-adjusting brakes adjust themselves as needed to be in the optimum position. Manual brakes must be adjusted manually. |
| Installation | Self-adjusting brakes are easier to install than hydraulic brakes. |
| Maintenance | Self-adjusting brakes self-adjust during every forward stop, providing up to 50% better braking distance and preventing premature brake line and magnet wear. |
| Durability | Self-adjusting brakes may not last as long as manually adjusted brakes. |
| Cost | Self-adjusting brakes have a higher upfront cost compared to manual brakes. |
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What You'll Learn
Forward Self-Adjusting (FSA) vs Manual Adjusting Electric Brakes
Electric drum brakes are the most common braking system for trailers and fifth-wheels due to their reliability and low cost. They work by using two brake shoes with friction material (brake lining) attached. An adjuster joins the two shoes together at the bottom. When an electric current from the brake controller in the cab of the tow vehicle energizes an electromagnet connected to an actuating arm, the magnet is attracted to the rotating surface of the drum. This causes the actuating arm to move and press the brake shoes against the drum, creating friction that slows the wheels.
However, the friction caused by activating the brakes leads to the brake linings and drums wearing down, creating a gap between them and reducing brake performance. Self-adjusting brakes are designed to mitigate this issue. Forward Self-Adjusting (FSA) brakes are one of the two main types of electric brake assemblies for axles 7K and below, the other being manual-adjusting brakes. FSA brakes automatically adjust themselves as needed to be in the optimum position. This is achieved through a device on the adjustment wheel that prevents the shoes from adjusting back inward. Manual brakes, on the other hand, must be adjusted manually via the star adjuster on the back side of the brake assembly.
FSA brakes are becoming more popular due to reduced maintenance requirements. However, because they are always adjusted to perform at their best, they may not last as long as manually adjusted brakes, which wear slower if not adjusted regularly. FSA brakes can be identified by a wire running from about 9 o'clock to 1 o'clock with a banjo-like fitting on the 1 o'clock side.
To install self-adjusting brakes, it takes about an hour per wheel, including greasing the bearings. While installation instructions may not be included, the necessary information can usually be found in the Electric Brakes Owner's and Service Manual. Two brake assembly sizes are available: 12-by-2-inch for trailer axles rated between 4,000 and 7,000 pounds, and 10-by-2.25-inch for 3,500-pound-rated axles.
To manually adjust standard electric brakes, the procedure requires raising the vehicle, safely supporting the frame, accessing behind the wheels, and adjusting with a special brake tool. This process should be performed after the first 200 miles and then every 3,000 miles. While not difficult, it adds maintenance costs if done by a professional.
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Installation
Self-adjusting electric trailer brakes are a convenient option for those who frequently use trailers. They are designed to adjust automatically, ensuring optimal performance and safety while towing. While the installation process may vary slightly depending on the specific product and trailer, here is a step-by-step guide on how to install self-adjusting electric trailer brakes:
- Prepare the Trailer: Park the trailer on a level surface and engage the parking brake. Ensure the trailer is securely blocked or chocked to prevent any accidental movement during the installation process.
- Access the Brakes: Depending on the trailer's design, you may need to jack up one side of the trailer to access the brakes. Place the jack under the trailer frame, not the axle, and raise it until the wheel can spin freely. For safety, it is recommended to use a jack stand for additional support.
- Remove Brake Components: Carefully remove the wheel and any necessary components to access the brake assembly. This may involve removing the brake drum, brake shoes, or brake pads. Keep the components organised and safely aside, as you will need to reinstall them later.
- Install the Self-Adjusting Brake Kit: Refer to the manufacturer's instructions for the specific self-adjusting brake kit you have purchased. This may involve mounting new brake components, such as an electric brake controller, actuating arm, or electromagnet assembly. Ensure all parts are securely attached and connected according to the instructions.
- Adjust the Brakes: Self-adjusting brakes typically have an automatic adjustment feature. However, initial adjustments may be necessary. Consult the manufacturer's instructions for any specific steps required for your particular brake system.
- Grease the Bearings: As mentioned in the Lippert Components test, greasing the bearings is an important step in the installation process. This helps ensure smooth operation and prolongs the life of the bearings.
- Reassemble the Wheel and Components: Reinstall the wheel and any components that were removed earlier. Ensure that all parts are securely fastened and torqued to the manufacturer's specifications.
- Test the Brakes: Once the installation is complete, test the brakes to ensure they are functioning correctly. This may involve a road test, where you slowly drive the trailer and apply the brakes at a safe speed. Adjustments may be needed to ensure optimal performance.
- Final Checks: After testing, perform final checks to ensure all components are securely fastened and that there are no leaks or damage to any parts. Consult the manufacturer's post-installation checklist, if provided, to ensure nothing has been missed.
It is important to note that working on trailer brakes can be complex and requires a good understanding of brake systems and safety procedures. If you are unsure or uncomfortable with any part of the installation process, it is always recommended to consult a professional technician for assistance. Additionally, regular maintenance and adjustments, as outlined by the manufacturer, are crucial to ensure the ongoing performance and safety of your self-adjusting electric trailer brakes.
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Maintenance
Initial Setup and Adjustment:
Firstly, it is crucial to perform an initial manual adjustment during the installation of self-adjusting brakes. This initial setup ensures that the brakes are functioning correctly from the start. The process involves raising the vehicle, accessing the brake components, and making the necessary adjustments with specialised tools. It is recommended to refer to the manufacturer's instructions or seek professional assistance if you are unfamiliar with the procedure.
Regular Maintenance Checks:
For ongoing maintenance, it is advised to inspect self-adjusting trailer brakes periodically. While the specific intervals may vary, a general guideline is to check and adjust the brakes every 3,000 miles or 3 months, depending on towing frequency. This maintenance routine includes tasks such as checking brake pads for wear, ensuring proper engagement, and verifying the torque on trailer tire nuts.
Testing and Adjustment:
To test the effectiveness of self-adjusting brakes, you can perform a brake test by driving at a controlled speed and applying the brakes to evaluate their performance. If the brakes feel soft or unresponsive, an adjustment may be necessary. Adjusting self-adjusting brakes is similar to adjusting manual brakes and involves using tools like a trailer brake spoon or a flathead screwdriver to turn the star wheel adjuster. Turning the adjuster one click at a time and checking the free spinning of the tire ensures the adjustment is accurate.
Cleaning and Lubrication:
Proper cleaning and lubrication of the brake components are vital to preventing issues like seized threads. Regularly cleaning the brakes and repacking them with grease or lubricant can help maintain their functionality and longevity.
Professional Assistance:
If you are uncomfortable with performing brake adjustments or inspections, it is always recommended to seek professional assistance. While it adds to the maintenance cost, it ensures that the brakes are correctly maintained and can provide peace of mind.
By following these maintenance guidelines, you can help ensure the safe operation of your trailer and maximise the effectiveness and longevity of self-adjusting electric trailer brakes.
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Testing Effectiveness
Self-adjusting electric trailer brakes are brakes that automatically adjust to perform at their best. Forward Self-Adjusting (FSA) brakes, for example, adjust themselves as needed to be in the optimum position. This is in contrast to manual brakes, which require manual adjustments via a star wheel adjuster or similar tool.
To test the effectiveness of self-adjusting trailer brakes, Lippert Components installed the brake components on a 33-foot travel trailer. The installation took about an hour per wheel, including greasing the bearings. The process is within the capability of trailer owners who are familiar with brake maintenance. The test trailer was equipped with LCI axles, rated at 5,200 pounds, and fitted with 12-by-2-inch electric drum brakes.
The installation process for the test included the following steps:
- The drum was slid in place, and the outer bearing, flat washer, and castle nut were installed on the spindle.
- The castle nut was tightened to 50 lb-ft while slowly rotating the drum.
- The castle nut was then loosened and finger-tightened until snug.
- A new cotter pin was inserted into the hole in the spindle. If the tabs on the castle nut do not line up with the hole in the spindle, slightly loosen the castle nut until the cotter pin can be inserted.
- With the cotter pin installed, the castle nut should be free to move slightly.
- The wheels were then reinstalled, and the lug nuts tightened to the torque specification and sequence in the trailer owner’s manual.
- The lug nuts’ torque was rechecked after the first 50 miles and again after the next 50 miles.
After the installation, the test trailer's drums showed only minor wear and could be reused.
It is important to note that self-adjusting brakes may not last as long as manually adjusted brakes. This is because manually adjusted brakes, if not adjusted regularly, are not used to their full potential, and the shoes wear slower.
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Adjusting Trailer Brakes
Electric trailer brakes use electrical signals, electromagnets, and brake pads to help the trailer stop while towing. The built-in electromagnets draw power from the vehicle to squeeze the brake pads. As power increases, the electromagnets apply more stopping force. To regulate the power to the electric trailer brakes, a brake controller is used, allowing the driver to monitor and control the trailer brakes.
Forward Self-Adjusting (FSA) brakes are automatically adjusted to perform at their best, so they are always in the optimum position. Manual brakes, on the other hand, must be adjusted manually using a star wheel adjuster. This adjuster is typically located below the brake drum, and can be turned with a trailer brake spoon, brake adjustment tool, or a flathead screwdriver.
To adjust the trailer brakes, first, jack up one side of the trailer, placing the jack under the trailer frame for support. Raise the jack until the wheel is able to spin freely, and secure it with a jack stand. Next, remove any covers, caps, or plugs to access the brake chamber and adjustment wheel. Then, using a trailer brake spoon or similar tool, turn the star wheel adjuster inside the brake chamber. This will tighten the brake pads or shoes. Turn the wheel one click at a time, spinning the tire between each click to ensure it spins freely. Once the trailer tire becomes difficult to turn, stop tightening the adjuster. The tire should still spin freely but with a slight scraping sound, indicating that the trailer brake pads are properly engaged. Finally, replace the cover and check the torque on your trailer tire nuts. Repeat this process on the other side of the trailer.
Self-adjusting electric brakes can also be adjusted by operating them with the manual lever on the brake controller while travelling at a slower speed of around 20 mph. Apply the brakes fully with the lever and release, repeating several times without overheating the brakes.
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Frequently asked questions
Self-adjusting electric trailer brakes are brakes that will adjust themselves as needed to be in the optimum position. They are easier to install than hydraulic brakes and provide up to 50% better braking distance.
Self-adjusting electric trailer brakes use two brake shoes with friction material (brake lining). An adjuster joins the two shoes together. An electromagnet, connected to an actuating arm, is energised by an electric current from the brake controller in the cab of the tow vehicle. When energised, the magnet attracts the rotating surface of the drum, causing the actuating arm to move and press the brake shoes against the drum.
Self-adjusting electric trailer brakes provide better braking safety, helping prevent premature brake line and magnet wear. They also save you from the hassle of manual adjustments.
One possible drawback of self-adjusting electric trailer brakes is that they may not last as long as manually adjusted brakes. This is because manually adjusted brakes, if not adjusted regularly, are not being used to their full potential and the shoes wear slower.
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