Otis Singleton
Electric over hydraulic trailer brakes are an advanced braking system that combines the control of electric braking mechanisms with the superior stopping power of hydraulic brakes. This system is designed to address the limitations of traditional electric brakes, which are prone to faults and violations, especially in demanding conditions such as hotshot trucking. Electric over hydraulic brakes offer improved performance, reliability, and safety, making them a preferred choice for heavy-duty and extensive trailer use. They are compatible with various trailer types, including utility, boat, and RV trailers, and provide smooth and proportional braking. The system consists of a brake controller in the truck, an electric over hydraulic brake actuator, and hydraulic disc or drum brakes on the trailer wheels.
| Characteristics | Values |
|---|---|
| Combination | Control of electric braking systems with the stopping power of hydraulic brakes |
| Comparison with electric brakes | More expensive upfront, better performance, more reliable, lower long-term costs |
| Installation | 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 |
| Wiring | Electric brake controller wired into the truck, the brake actuator wired into the 7-pin connector on the trailer |
| Pressure lines | High-pressure lines installed between the brake actuator and the disc brakes on each wheel |
| Compatibility | Utility, boat, livestock, horse, and 5th Wheel RVs |
| Safety | Reduces the risk of trailer sway and enables more effective braking |
| Adjustability | Adjustable to suit different towing conditions and preferences |
| Towing capacity | Suitable for larger trailers and heavy loads |
| Regulatory compliance | Adheres to CFR-393 Federal Braking Requirements and aligns with Department of Transportation (D.O.T.) regulations |
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$309.99
What You'll Learn
Electric over hydraulic brakes vs. regular electric brakes
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 and heavy-duty towing applications. They are also ideal for those who use their trailers daily or extensively.
Electric over hydraulic brakes offer a significant reduction in electrical connections at the hubs, minimising issues caused by debris and corrosion. They also provide stronger stopping power compared to regular electric brakes, enhancing overall braking efficiency. Braking is proportional to speed, and the system ensures equal and full pressure on all wheel positions, resulting in consistent braking. This eliminates the need for repeated adjustments to the brake controller, which is common with electric brakes as they age.
In contrast, regular electric brakes have been the more cost-effective and popular choice for trailers, especially those not used for heavy commercial use. However, their design and durability issues under extensive use have led to problems and Department of Transportation (DOT) violations in the hotshot trucking industry. 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 faults and replacements.
While electric over hydraulic brakes are more expensive upfront, they offer better performance, reliability, and lower long-term costs due to reduced maintenance and fewer replacements. This makes them a superior choice for heavy-duty use, providing stronger braking force and safer towing.
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Installation process
Electric over hydraulic trailer brakes combine the control of electric braking systems with the stopping power of hydraulic brakes. This system eliminates many of the common issues associated with traditional electric brakes, making them a superior choice for heavy-duty use.
The installation process for electric over hydraulic trailer brakes involves several steps to ensure proper functioning and safety. Here is a detailed guide on how to install them:
- Jack up the trailer and remove the wheels: Use a jack to lift the trailer according to the manufacturer's recommendations. This step provides access to the brake assembly.
- Remove the old brake components: Take out the existing electric brake drums, backing plates, and any other relevant parts. Ensure you have the necessary tools and safety equipment for this process.
- Install the caliper bracket: Mount the caliper bracket onto the axle's brake flange. This bracket will serve as the base for the new brake calipers.
- Prepare the bearings: Pack new bearings with grease and install them, along with seals, into the integrated hub rotor. Then, mount this assembly onto the spindle.
- Mount the brake calipers: Secure the brake calipers onto the caliper bracket. Ensure they are firmly attached and aligned correctly.
- Determine the location for the electric over hydraulic actuator: Consider the physical size of the actuator and its weatherproofing capabilities. Choose a location that balances accessibility and protection from the elements.
- Install and wire the actuator: Follow the manufacturer's instructions to install and wire the electric over hydraulic actuator. This component is crucial for converting electrical signals into hydraulic pressure for the brakes.
- Connect the actuator to the calipers: Use steel brake line tubing to run from the actuator to the calipers. Ensure there is enough tubing to accommodate the necessary flexibility.
- Reinstall the wheels: Once all the components are connected, bleed the brakes to remove any air bubbles, test the system, and reinstall the wheels.
- Test the trailer: After installing the wheels, thoroughly test the trailer's braking system to ensure it functions correctly and safely. Adjustments may be needed to optimize braking performance.
It is important to consult the specific instructions provided by the manufacturer of your electric over hydraulic trailer brake system, as there may be variations in the installation process. Additionally, always prioritize safety and follow recommended practices when working on trailer brakes.
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Improved safety and performance
Electric over hydraulic brakes offers a range of safety and performance benefits over traditional electric brakes, particularly for trailers used in demanding conditions or heavy-duty commercial applications.
One of the primary advantages is the reduction in electrical connections at the hubs, minimising potential issues caused by debris and corrosion. By stopping the electrical connections at the brake booster, the risk of electrical faults at the hubs is significantly reduced. This enhances the overall reliability of the braking system, ensuring consistent and efficient performance.
Electric over hydraulic brakes also provide superior stopping power compared to regular electric brakes. The hydraulic brake fluid, similar to car braking systems, increases braking efficiency. When the tow vehicle brakes are applied, a signal is sent to the brake booster, which activates the brake pump to stop the trailer. This results in almost instantaneous braking, reducing response time and improving safety.
The system is especially beneficial for downhill driving, as the trailer brakes engage first, providing greater control and stability. Additionally, the ability to adjust the brake controller allows for customisation based on the load and driving conditions, further enhancing safety and performance.
For those in the trucking industry or using trailers extensively, electric over hydraulic brakes offer improved durability and lower long-term maintenance costs. By eliminating the issues associated with constant movement and road debris on electric brake magnets and wires, this system provides better performance and peace of mind on the road.
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Compatibility
Electric over hydraulic trailer brakes are an advanced braking system that combines the control of electric braking systems with the superior stopping power of hydraulic brakes. This makes them highly compatible with trailers used in demanding conditions, heavy-duty use, and extensive travel, such as in the hotshot trucking industry.
One of the key benefits of electric over hydraulic brakes is their compatibility with various trailer setups. They are designed to work with both drum and disc brakes, offering flexibility to trailer owners. Additionally, these brakes are compatible with trailers that have no pre-existing braking systems, providing an option to enhance safety.
When considering compatibility, it is important to select the appropriate electric over hydraulic actuator. These actuators are available in different types, such as those compatible with disc brakes and those that install on the tongue of the trailer frame. Some actuators also come with breakaway kits, which are crucial for trailer safety. Federal law mandates the inclusion of a breakaway kit to activate the trailer's brakes in the event of separation from the tow vehicle.
The compatibility of electric over hydraulic brakes extends to towing applications, where they ensure smooth and proportional braking. These brakes allow the towed vehicle to synchronize its brakes with the towing vehicle, making them ideal for trailers and recreational vehicles (RVs). To achieve this synchronization, the system relies on an electric brake controller installed in the towing vehicle, allowing the driver to adjust the braking force as needed.
While electric over hydraulic brakes offer broad compatibility, it is important to consult manufacturer recommendations for specific instructions and considerations, such as weatherproofing and installation procedures. Additionally, compliance with regulatory requirements, such as Department of Transportation (DOT) regulations, is essential to ensure legal and safe operation.
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$188.99
Maintenance and cost
Electric over hydraulic trailer brakes offers a robust braking option for trailers, especially those used in demanding conditions. While this system is more expensive upfront, it offers better performance and reliability, and can lead to lower long-term costs.
Maintenance of electric over hydraulic brakes is generally straightforward. On axles with disc brakes, components like calipers and brake pads are easily accessible and can be inspected and replaced without hassle. Bleeding the system if air gets into the lines is also a simple process. However, some users have reported issues with their electric over hydraulic brakes, including error messages, intermittent functioning, and compatibility issues with certain vehicles.
In terms of cost, electric over hydraulic brakes typically carry a higher initial expense compared to regular electric brakes. For example, upgrading from a 10,000-pound electric brake axle to an electric-over-hydraulic system can cost approximately $1,600 more. However, this investment can pay off in the long run, as electric brakes may require more frequent replacements and maintenance, leading to higher overall costs. Electric brakes are also more prone to Department of Transportation (DOT) violations due to their design and durability issues under extensive use.
For those who use their trailers extensively, such as in the hotshot trucking industry, electric over hydraulic brakes can be a wise investment. They provide stronger stopping power, enhancing overall braking efficiency and safety on the road. Additionally, electric over hydraulic brakes have fewer electrical connections at the hubs, reducing the likelihood of issues caused by debris and corrosion.
Upgrading to electric over hydraulic brakes can offer improved performance, reduced maintenance concerns, and potentially lower long-term expenses when compared to traditional electric brake systems. However, it is important to consider the specific requirements and usage patterns of your trailer to make an informed decision.
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Frequently asked questions
Electric-over-hydraulic trailer brakes combine the control of electric braking systems with the stopping power of hydraulic brakes. They are ideal for trailers used in demanding conditions and heavy-duty use.
Electric-over-hydraulic trailer brakes use an electric brake controller installed in the towing vehicle, which allows the driver to activate and control the braking force on the trailer. This controller sends an electric signal to the electric-over-hydraulic brake actuator, which converts the signal into hydraulic pressure to activate the brakes.
Electric-over-hydraulic trailer brakes offer improved performance, reliability, and safety compared to traditional electric or hydraulic brakes. They have faster response times, smoother braking, and stronger stopping power. They also reduce electrical issues at the hubs and minimise the risk of trailer sway.
The installation process involves wiring the tow vehicle for electric brakes and installing hydraulic brake lines and brakes on the trailer. You will need a brake controller in the truck, an electric-over-hydraulic brake actuator on the trailer, and hydraulic disc brakes on the trailer wheels. Ensure you have the correct parts and follow the manufacturer's recommendations for installation.
