LIT-018-00 – Brakerite Electric Hydraulic Brake Actuation System

SEOCONTENT-START

BRAKE RITE®
ELECTRIC/HYDRAULIC ACTUATION
OPERATION MAINTENANCE SERVICE MANUAL
BRAKERITE ELECTRIC HYDRAULIC BRAKE ACTUATION SYSTEM
www.dexteraxle.com
Introduction ……………………………………………………… 2
Safety lnformation …………………………………………………….. 2
Overview …………………………………………………………………. 2
Electrical ………………………………………………………….. 3
Installation ……………………………………………………….. 4
Operation …………………………………………………………. 6
Service and Maintenance …………………………………………… 6
Troubleshooting ………………………………………………………… 6
Introduction
Thank you for purchasing a Dexter BrakeRite Actuator system. Dexter
has been a pioneer in development of brake actuation and brakes.
Dexter’s BrakeRite systems are state of the art ELECTRIC over
HYDRAULIC BRAKE (EHB) systems.
& CAUTION
· Verify wire connections are correct before energizing or
powering BrakeRite system. Improper wiring can damage
actuation system causing system failure.
· Failure to use proper gauge wire can result in improper operation
or failure of components and braking ability. For runs of wire
more than twenty (20) feet, larger gauge wire should be used.
· Proper grounding must be observed. Grounding to trailer frame
is not acceptable. See provided diagrams for proper wiring.
Dexter’s BrakeRite systems use electric power from towing vehicle to drive
hydraulic power source. In breakaway situations, electric power is supplied
by a battery if trailer is completely separated from tow vehicle. This battery
is charged by built in control circuitry in Dexter’s BrakeRite. All BrakeRite
systems are actuated one of three ways; by brake pedal of tow vehicle
being depressed, manual over-ride switch on in-cab brake controller, or
during breakaway situation when breakaway switch is activated. Both
manual override and breakaway systems are required by Federal Law.
All Dexter BrakeRite systems require in-cab electric brake controller
which is not provided in these systems. These actuators will operate
from most electric brake controllers WHEN PROPERLY INSTALLED.
Proper electrical wiring is critical for performance of any BrakeRite system.
Improper wiring can damage actuation system causing system failure.
A pure ground and direct power (+12 VCD) with fuse or circuit breaker
(30 amp) are necessary for proper performance. Adequate wire size, 12
Gauge Stranded Automotive or heavier, is required as long runs increase
line loss. Line loss and poor grounding will result in poor performance
or total loss of braking. Connection for Brake Rite II SD and BrakeRite
Plug and Play systems are provided by pre-wired harnesses and plug
connectors are keyed so they cannot be connected wrong, however, if plug
between tow vehicle and trailer is not wired properly, unit will not function
properly, or at all. See proper wiring diagram for assistance.
Safety Information
■ Installation, maintenance, or repair should ONLY be performed by
qualified persons who have training or knowledge of the systems.
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■ When installing, maintaining, or repairing Dexter equipment, wear
eye protection and other necessary personal protective equipment.
■ Dexter equipment must be maintained in safe working order at
all times. Trailer equipment should be inspected before, during,
and after use for wear and damage.
■ Inspect trailer and equipment before each use.
■ Check that brake fluid level is within 3/8″ from filter opening.
■ Verify breakaway protection is working properly.
■ Confirm breakaway battery is charged properly.
■ Confirm brake actuator being used can supply enough hydraulic
pressure and volume to actuate disc brakes. As a common rule,
disc brakes require more pressure and larger volume of fluid
than drum brakes of same size.
■ Use DOT3, DOT4 or DOT 5 brake fluid. Failure to use correct
brake fluid may result in brake failure.
& CAUTION
DOTS fluid can be used with new systems only. This Includes
brake lines and brakes. Flush BrakeRlte with mineral oil before
filling with DOTS fluid. Once DOTS brake fluid Is used, only use
DOTS fluid and do not use DOT3 or DOT 4 fluids. Do not use
DOTS fluid on a used BrakeRlte.
■ Be familiar with state laws in operation of towed vehicles,
especially with regard to brake and braking requirements. Towing
a trailer may require additional braking time and distance. Allow
for this in driving habits while towing.
■ Make certain equipped trailer is safely supported at all times
during installation, maintenance or repair.
■ After every hookup, test and confirm trailer brake system is
operating correctly and adequately before transportation on roads
Before each towing, perform these steps:
1. Check brake fluid reservoir is within 3/8″ from filler opening of
fresh, clean DOT3, DOT4 or DOT 5 brake fluid.
2. Check for leaks. Service as required.
3. Examine actuator for wear, or other damage. Have affected
components serviced. Verify actuator mounting bolts are tight.
4. Test actuator and brake function before transport. Failure to
properly adjust brakes will result in loss of braking.
There are no adjustments on BrakeRite actuators. BrakeRites are
shipped with tamper proof seals between cover and casting. Warranty is
void if seals are broken. Dexter genuine replacement parts are available
at dexteraxle.com
Overview
All BrakeRite units are similar, differences are with electronics. BrakeRite
EHB has an ECB (electronic control board) built within unit and has five
wires exiting. Termination of these five wires is performed by installer
per wiring diagram. If not properly connected, unit will not perform
properly or at all. BrakeRite II has no ECB and has a 3 wire cable with
Female Weather Pack plug; therefore it requires a control module. With
BRAKERITE SERVICE MANUAL
Electric Hydraulic Brake Actuation Systems
BrakeRite II SD (Severe Duty) control modules are used.
All BrakeRite models use the same electric motor driven piston pump
and electronic controlled pressure relief valve. Exterior appearance
between them is very similar, only wires exiting housing, control board,
and distinct Model Markings are different.
SD Control Kit for BrakeRite II is same control circuitry as BrakeRite
EHB. However efforts to improve installation efficiencies and reliability
SD Control kit consists of; one SD control module, one 1/0 harness with
7-pin RV plug 7-pin RV receptacle with three wiretap with Weather Pack
plug, and one battery cable with Weather Pack plug. All electrical circuitry
are individual circuits are keyed so wires cannot be connected improperly.
Great importance must be placed upon proper wiring in tow vehicle plug.
Brake pressure for all BrakeRite models are controlled by most in-cab
electronic brake controllers. Brake performance is selected by driver. Manual
override can also be applied if driver wishes to apply only trailer brakes.
Federal law requires ALL trailers with brakes have ability to apply brakes in
event trailer become uncoupled from tow vehicle. This requires a breakaway
switch and power source (battery) on trailer. All BrakeRite systems have
circuitry for breakaway, however, breakaway switches are provided only with
SD control kits and no breakaway batteries are supplied with any kits.
Electrical
All BrakeRite models are 12 Volt DC with negative ground. Improper
connections and grounding may result in system damage. For both
BrakeRite EHB & BrakeRite II SD, 12 gauge or larger wire must be run from
tow vehicle battery to BrakeRite with a fuse or circuit breaker for protection.
BRAKERITE EHB WIRING INDEX
TO TOW VEHICLE
BLACK: CONSTANT 12V POSITIVE FROM TOW VEHICLE
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•~ G;tCII.BWlll: TO ‘ll”l£1.1 k~ FU~AMBLUE:
IN CAB CONTROL, VARIABLE CURRENT
TO BREAKAWAY CONNECTION
BROWN· TO BREAKAWAY SWITCH
VIOLET: TO POSITIVE POST ON BREAKAWAY
BATTERY, AND TO BREAKAWAY SWITCH
TRAILER PLUG
BLACK
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Control leads for BrakeRite EHB & BrakeRite II SD require 16 gauge or larger
wires be used. If undersized wiring is used for power leads, low voltages may
occur with slow response times and poor performance of brake system.
All BrakeRite models must use a BREAKAWAY BATTERY OF AT LEAST 9
AMP HOURS. For RV applications, the house battery may be used as the
breakaway battery as long as the above conditions are met at all times.
Breakaway battery serves to operate all BrakeRite models as a peaking
battery for applications and to supply power in a breakaway condition.
BrakeRite II supplies power for both breakaway conditions and also
supplies power to operate the brake system. All three systems have
internal chargers to maintain charge on battery from tow vehicle.
Breakaway switch (circuit) is required by law. For standard BrakeRite
EHB kits, neither switch nor batteries are included. For standard
BrakeRite II kits, breakaway switch is included while batteries are not.
Breakaway cables and batteries can be ordered separately if needed.
When properly installed, breakaway switch applies trailer brakes in
event trailer becomes un-coupled from tow vehicle. Closing of a circuit
is required to activate breakaway function. Breakaway switch is normally
close switch held OPEN by a plastic key. A cable is attached to key and
to tow vehicle. If units become uncoupled, cable pulls key from switch
closing circuit activating breakaway function and applying trailer brakes.
ECB (electronic control board) has a battery protection circuit to assure
breakaway (auxiliary) battery maintains a charge at all times and
prevents a surge charge which could damage battery. Protection is also
designed into board to prevent power draw from auxiliary battery to tow
vehicles electrical system.
BRAKERITE EHB
ELEC/HYD
ACTUATOR
Figure 1 – BrakeRite EHB Wiring
Diagram
BRAKERITE EHB CONVERTER
REQUIRED FOR FORD/CHEVY
INTEGRAL TOWING SYSTEMS
YEARS 2006 1/2 AND BEYOND
CHEVY/FORD
ADAPTER (EHB)
r— F~~ ~~=–BLUE—=~~~ ,
BROWN ~ n ‘)
—-~VIOLET ~ u ELECTRONIC BRAKE
CONTROL
TOW VEHICLE
BATTERY
12VOLT
TO TOW VEHICLE
BRAKERITE SERVICE MANUAL
Electric Hydraulic Brake Actuation Systems
WHiTIE
‘Tl! VIOLET
r , r ,
0 (±;)
BREAK-AWAY
BATTERY
12VOLT
9 AMP-HOUR MIN
BREAK-AWAY
SWITCH
(NOT POLARITY SENSITIVE)
(WIRE COLOR MAY VARY)
2019.01 I 3
Figure 2 – BrakeRite II SD
Wiring Diagram
0 ©
BREAK-AWAY
BATTERY
12 VOLT
9 AMP HOUR MIN
BRAKERITE II
ELEC/HYD
ACTUATOR
Installation
BLACK
BRAKE RITE
SD CONTROL
MODULE
OJ [3J [}] 8J
Mounting location of any BrakeRite model is at discretion of installer,
however accessibility for service, protection from damage, and ability to
minimize length while protecting brake lines are factors to be considered.
Approximate physical envelope for power unit is 6″ front to back, 7-1/ 4
left to right, and 9-1/8 high. Two sets of mounting holes are provided in
power unit; one set of four located on bottom (1/ 4 – 20 UNC x 5/8 deep)
and one set of three located on back (5/16 – 18 UNC x 5/8 deep). The
last page of this manual has a 1: 1 scale drawing of power unit mounting
holes. Drawing can be used as a marking and drilling diagram for custom
bracketry and mounting hardware. Verify scale before use.
All BrakeRites have a 1/8 – 27 NPTF port located on lower front of
housing and a straight 1/8 – 27 NPTF Male by #3 Female Inverted Tube
seat (3/ 4 – 24 NPTF) adapter. When installing any adapter, DO NOT
USE TEFLON PIPE TAPE as properly mated brass fitting joints DO NOT
require a sealant. Route brake lines to axles per Brake Line Fitting Kit
manufacturer’s instructions. Use of flexible tubing/hose should be kept
to a minimum. Using too much flexible tubing will cause brake delay.
Secure all tubing for maximum protection from pinching, vibration,
corrosion, or road hazards. When bending and flaring steel tubing,
always use proper tools to assure sound connections and prevent
kinked lines. Kinked and/or damaged brake lines can cause restriction
in flow resulting in poor braking or no brakes at all.
Depending on brake system chosen, there are various approaches
to be considered for electrical connections. Though Dexter produces
BrakeRite systems, Dexter has NO control over how towing vehicle or
trailer has been wired or its color coding. Therefore, when installing
any BrakeRite system, it is important that all wiring is connected per
2019.07 I 4
SD CONTROL MODULE INDEX
1. BREAK-AWAY BATTERY LEADS
~is . WM!,~: @,’,l@IJM@
18 – BLACK: CONSTANT +12DC
2. BRAKERITE II ACTUATOR
~-~ 0 WL’-!lni,: @,’,l@IJIM@
28 – GREEN W/ WL’-!li?il!: SOLENOID
2C – BLUE W/ WleJOi,1~: MOTOR
3. BREAK-AWAY SWITCH
3A – RED: (NOT POLAR SENSITIVE)
3B – BROWN: (NOT POLAR SENSITIVE)
4. INPUT-VEHICLE
~~ . ,”:9L’-!li””!1′: l/ll,’,l@l.i!/>!1Dl
4B – BLUE: BRAKE CONTROLLER
4C – BLACK: CONSTANT +12DC
BRAKERITE SD CONVERTER
REQUIRED FOR FORD/CHEVY
INTEGRAL TOWING SYSTEMS
YEARS 2006 1/2 AND BEYOND
BLACK ~ n ‘)
BLACK ~W~ SWITCH
(NOT POLARITY SENSITIVE)
(WIRE COLOR MAY VARY)
0
CIRCUIT
BREAKER
BLACK
TOW VEHICLE
BATTERY
12 VOLT
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these instructions. While it is desirable to establish a ground between
frame, BrakeRite unit, and negative side of breakaway battery, NEVER
RELY SOLELY ON FRAME GROUNDING. Always use good ground leads
between ALL specified points. If rewiring from electric brakes, start wiring
as close to front of trailer as possible. A junction box, pin box, or 7-way
plug, are preferred starting locations. As electrical portion of installation
is carried out, make certain wires are properly routed, wrapped,
anchored, and protected to prevent damage, catching on road hazards,
or rubbing on frame components. When making connections in circuits,
other than plug-in connectors, desirable joint is a solder joint. If using
crimp-type joints, always use manufacturers recommended crimping
tools in accordance with manufacturer’s directions and always properly
wrap and protect all joints to prevent shorting and corrosion. Heat
shrinking joints also help prevent water causing shorts or corrosion.
BrakeRite EHB requires installer assure all wire are connected properly.
See wiring diagram Figure 1 for preferred method for electrical wiring.
This method requires an independent battery solely for brake system.
However, towed vehicle auxiliary batter can be used in place of
breakaway battery if it is in good condition and fully charged. NOTE: If
trailer has set for an extended period of time, auxiliary battery may have
been discharged excessively resulting in poor or no braking. If system
is being converted from electric brakes, remove as much old brake
wiring as possible and run new wires. This will ensure wires used are of
adequate size and give better operation of BrakeRite.
Function and size of five (5) wires exiting BrakeRite EBH are as follows:
■ White: 12 gauge, 12 VDC negative (-) system ground
■ Black: 12 gauge, 12 VDC positive ( +) system power in
BRAKERITE SERVICE MANUAL
Electric Hydraulic Brake Actuation Systems
■ Blue: 16 gauge, Brake Control Input (from in cab electronic
brake controller)
■ Brown: 16 gauge, Breakaway Input (from one lead of breakaway
switch)
■ Violet (Mauve): 14 gauge, 12 VDC Input/Output between Unit
and Breakaway battery. (2nd lead of breakaway switch is also
connected to 12 VDC positive of breakaway battery)
BrakeRite II SD and BrakeRite Plug and Play kits have a complete wiring
harness as a plug-in system and all connections within have been
preselected so that upon installation connections are simply plugged in. It
is crucial that 7-pin RV receptacle on tow vehicle is wired per Figure 4.
Two basic options are whether to use an auxiliary battery on trailer, if
one is available, or to install a separate breakaway battery (preferred).
No battery is supplied with standard kits. Figure 2 illustrates preferred
method (separate breakaway battery). Trailer auxiliary battery can
be used in place of breakaway battery if it is in good condition, fully
charged.
7-WAYTRAILER/TRUCK CONNECTION
BLACK
+12V
TRAILER CABLE END
(front face of connector)
Plug Configuration for
BrakeRite U SD Harness
0 0
TRUCK PLUG END
(front face of connector)
Required Mating
Receptacle
Figure 4 – Most Common Factory Installed Wiring Arrangement
4-Pin Flat Connector on tow vehicle must be wired as shown in Figure
5. Similar to SD kit, options that are left is whether to use an auxiliary
battery on trailer, if one is available or to install a separate breakaway
battery (preferred). No battery is supplied with standard kit. Figure 2
illustrates preferred method (separate breakaway battery) however;
trailer auxiliary battery can be used in place of breakaway battery if it is
in good condition, fully charged and meets amperage requirements.
4 PIN FLAT CONNECTOR – BRAKERITE II RF CONNECTION
TRUCK CONNECTOR TRAILER CONNECTOR
GRICFI,,/ GRFEN
BROWN [ L :I I BROWN
:::-1r:: ·:.i,,;r.:;:
GREEN – RIGHT TURN I BRAKES
FT (FS
BROWN – TAIL LIGHTS
WIHJii’~ • @lfi(Ol!JIINIIOJ
Figure 5 – Industry Standard Four Pin Configuration
After unit has been mounted, brake lines installed, and electrical
connection completed, system start-up can begin. Remove one filler
cap and fill reservoir to within 3/8 of filler cap opening. (Either cap can
BRAKERITE SERVICE MANUAL
Electric Hydraulic Brake Actuation Systems
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be used as both fill same reservoir) Fill reservoir with NEW DOT3, DOT4
or DOT5 BRAKE FLUID. Never reuse brake fluid that has been salvaged
or removed from another system. Contaminated brake fluid may cause
damage resulting in system failure. Never mix grades of DOT fluid.
All air must be removed from brakes and brake lines prior to trailer
operation. To bleed brakes, remove key from breakaway switch to start
unit. Starting with brake furthest from actuator, open bleeder screw and
allow it to remain open until brake fluid releases free of air bubbles.
Close bleeder screw and move to next brake closer to BrakeRite until
all brakes have been bled. While performing bleeding process, monitor
fluid level in reservoir so air is not pumped into brake lines because of
low fluid. Running BrakeRite pump dry can damage motor. To prevent
spilling brake fluid on ground, place one end of length of plastic tubing
over end of bleeder screw and other end should be placed into a
container so that fluid flow can be monitored for bubbles.
& CAUTION
· Use fresh DOT3 or DOT4 brake fluid from sealed container.
DO NOT reuse brake fluid. Failure to use fresh brake fluid
increases chance of brake failure.
• Use care when handling brake fluid. DO NOT allow brake fluid
to contact painted surfaces. It will damage surface finishes.
Wipe up spills immediately and wash area with water.
· This Is a high pressure system. ALL air must be removed. Any
air in brake lines will cause brakes not to function properly.
Bleed brake system completely.
After all brakes have been bled, replace key in breakaway switch.
& CAUTION
DOTS fluid can be used with new systems only. This Includes
brake lines and brakes. Flush BrakeRlte with mineral oll before
fllllng with DOTS fluid. Once DOTS brake fluid Is used, only use
DOTS fluid and do not use DOT3 or DOT 4 fluids. Do not use
DOTS fluid on a used BrakeRlte.
2019.01 I 5
Operation
When coupling trailer to tow vehicle always assure that two vehicles
are coupled in accordance with vehicle manufacturer’s instructions
and that all coupling devices and procedures conform to applicable
state and federal regulations. After units are properly coupled, connect
electrical plug. Assure that safety cable from breakaway switch on trailer
is connected to tow vehicle.
To assure proper connections have been made, most in-cab controllers
have some type of indicator showing electrical connections are
adequate. Consult in-cab controller manufacturer’s operator manual for
proper checking and setting procedures. Before moving vehicle depress
tow vehicle brake pedal, BrakeRite unit should start (audibly hear
unit). Release tow vehicle brake pedal and activate BrakeRite unit by
operating manual override on in-cab controller. Again, unit will be heard
running. With manual override, a tone change will occur as pressure
builds relative to activation amount initiated from override switch. Do
not attempt to move unit or trailer until brake system performs properly
in described tests above.
After system responds to tests previously described, proceed with
moving vehicle to establish feel for brake system and also to calibrate
brake response based upon instructions given in brake controller
manual. This adjustment should be performed in a parking lot or low
traffic area. Do not attempt to operate unit in congested traffic or on
major though fares until familiarized with feel and performance of brake
system. Every operator and every vehicle have unique requirements
and characteristics. Take time to be familiar with how unit feels,
performance, and proper operation and setting selections of brake
controller.
Trailer brakes are meant to assist tow vehicle in stopping of combined
units and are not intended to stop entire combined unit Two basic types
of In-Cab Electronic Brake Controllers exist. Inertia based controllers
create a small bias braking force when activated and modulates braking
forces of trailer relative to braking reaction created by tow vehicle. Inertia
controllers offer most desirable braking effect Another type is time based
controllers. Time based controllers turn on when tow vehicle’s brake pedal
is applied and braking for increases at a selected rate until it reaches
a maximum set point. This does not produce as smooth of braking as
inertia based controllers and is very speed sensitive. Time based brake
controllers are NOT recommended for this reason.
Manual override is required by law and should be fully understood for
proper and safe operation. This allows trailer brakes to be activated
without depressing tow vehicles brake pedal.
Service and Maintenance
Periodic inspection of electrical connectors, wiring, brake lines, and
hose for entire brake system to insure no abraded or bare wires,
damaged steel lines, or damaged hoses exist. During inspection assure
there are no loose or hanging objects that might drag or catch on during
transport.
EVERY time trailer is coupled to tow vehicle, check following items:
• Check fluid level in reservoir. Fluid level must be maintained
within 3/8 below filler opening. If brake fluid is required, add
only new, clean DOT3, DOT4 or DOT5 brake fluid. Use caution
when removing reservoir cap to prevent admission of any
2019.07 I 6
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contaminants into fluid reservoir.
• Check breakaway battery is charged and breakaway system
works. Test by pulling cable on breakaway switch. If vehicle
has been parked for long periods, breakaway battery may be
discharged. If this situation occurs, charge battery per trailer
manufacturer’s recommendations prior to using trailer. If battery
is discharged in cold environments, freezing battery, damage
may have occurred to battery.
• Inspect coupler and safety chains to assure they are fully
functional and for wear or damage. All equipment must meet
manufacturer’s specifications and all applicable laws.
All BrakeRite models are shipped from factory with tamper proof seals
between cover and casting. Warranty is void if these seals have been
broken. Genuine Dexter replacement parts are available at dexteraxle.com.
Troubleshooting
Experience has shown that virtually all problems with BrakeRite unit
are results of INCORRECT or FAILED WIRING. If problems arise, consult
applicable wiring diagram and inspect all wiring and terminations.
A bench test can be performed as follows. Connect Black wire to
positive(+) and White to negative(-) power source. Proceed to
momentarily tap Blue wire to positive(+) side of power source. Motor
should switch on briefly. Next momentarily tap Brown wire to positive(+)
side of power source. Motor should switch on briefly. If both tests work,
problems are not in BrakeRite unit. Wiring and other components should
be checked for problems.
ISSUE SOLUTION
Indicator on In-Cab Controller Inspect plug and wiring for open
shows no connection between circuit. Consult applicable wiring
tow vehicle and trailer diagram for proper connections.
Poor response time Check and add brake fluid as
required. Bleed brake lines and
devices. Check input for adequate
Charge (12VDC).
Inadequate or excessive trailer Adjust gain control on In-Cab
braking Controller
BrakeRite unit runs but does not Assure proper brake fluid level,
build pressure add fluid and bleed system as
required
BrakeRite unit does not run when Check breakaway battery charge
breakaway is pulled and assure wires are properly
connected
BrakeRite unit does not run Verify and connect wire
when in-cab manual override is connections in entire electrical
activated circuit.
BRAKERITE SERVICE MANUAL
Electric Hydraulic Brake Actuation Systems
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BRAKERITE MOUN TING
HOLE DIAGRAM
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~
2019.07
Together. Carrying what matters most.
www.dexteraxle.com
2900 Industrial Parkway East – Elkhart, IN 46516
Phone: 574-295-7888 – Fax: 574-295-8666
ISO 9001:2015 Certified
© 1990 – 2019 Dexter Axle Company. LIT-018-00