OPERATION MAINTENANCE SERVICE MANUAL
BRAKERITE ELECTRIC/HYDRAULIC BRAKE ACTUATION SYSTEM

www.dexteraxle.com

Introduction ................................................................2
Safety Information..............................................................2

Electrical.....................................................................3
Installation ..................................................................4
Operation ....................................................................7
Service and Maintenance..............................................7
Troubleshooting............................................................7
Limited Warranty..........................................................8
Mounting Template.......................................................9
Notes.........................................................................10

All BrakeRite systems require an in-cab electric brake controller which
is not provided. These actuators will operate from most electric brake
controllers WHEN PROPERLY INSTALLED.
Proper electrical wiring is critical for the performance of any BrakeRite
system. Improper wiring can damage the actuation system causing
system failure. A pure ground and direct power (+12 VDC) 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
BrakeRite 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 the plug between tow vehicle and trailer is
not wired properly, the unit will not function properly, or at all. See the
proper wiring diagram for assistance.

CAUTION

Locations...................................................................11

!

CAUTION

This is the safety alert symbol. It is used to alert you to potential
injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.

Introduction

CAUTION

Dexter BrakeRite systems should only be installed by a qualified
technician.
BrakeRite systems use electric power from the towing vehicle to drive the
hydraulic power source. In breakaway situations, electric power is supplied
by a battery if the trailer completely separates from the tow vehicle. An
internal control circuit charges this battery. All BrakeRite systems are
actuated in one of three ways: by brake pedal of the tow vehicle being
depressed, manual over-ride switch on an in-cab brake controller, or
during a breakaway situation when the breakaway switch is activated.
Federal Law requires both manual override and breakaway systems.

Please review and understand all installation manual instructions
before beginning installation. Many steps are sequential so it is
necessary to complete all elements as instructed.

Safety Information
ƒ Wear eye protection and other necessary personal protective
equipment when installing, maintaining, or repairing the unit.
ƒ 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.
ƒ Inspect trailer and equipment before each use.
ƒ Check that brake fluid level is within 3/8” from filter opening.

CAUTION
Do not overfill the fluid reservoir. The fluid will expand. Max fill
level is 3/8” below the bottom of the filler neck.

CAUTION
• Verify wire connections are correct before energizing or
powering the system. Improper wiring can damage the
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 20 feet, larger gauge wire should be used.

5”

.37

Air Gap

• Proper grounding must be observed. Grounding to trailer frame
is not acceptable. See the provided diagrams for proper wiring.

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BRAKERITE SERVICE MANUAL

Electric Hydraulic Brake Actuation Systems

ƒ Verify breakaway protection is working and charged properly.
ƒ 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 a larger volume of fluid
than drum brakes of the same size.

CAUTION
DOT5 fluid can be used with new systems only. This includes brake
lines and brakes. Flush the unit with mineral oil before filling with
DOT5 fluid. Once DOT5 brake fluid is used, only use DOT5 fluid and
do not use DOT3 or DOT 4 fluids. Do not use DOT5 fluid on a used
unit. Failure to use correct brake fluid may result in brake failure.
ƒ Be familiar with tow vehicle operation state laws, 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.
ƒ Confirm that trailer is safely equipped and supported at all times
during installation, maintenance, or repair.
ƒ After every hookup, test and confirm the trailer brake system is
operating correctly 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 proper brake fluid. Use caution when removing the
reservoir cap to prevent the admission of any contaminants into
the fluid reservoir.

2.

Check for leaks. Service as required.

3.

Examine unit 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 for BrakeRite actuators. Units are shipped
with tamper proof seals between cover and casting, if broken the
warranty is void.

Overview
All BrakeRite units are similar, differences are with electronics. BrakeRite
EHB and Plug and Play have an electronic control board built within
the unit. The EHB has 5 wires exiting, termination of these five wires
is performed by the installer per the wiring diagram. The Plug and
Play model has 3 cables exiting. If cables or wires are not properly
connected, the BrakeRite will not perform properly or at all. BrakeRite
SD has no ECB and has a single wiring harness with female weather
resistant plugs; therefore it requires a control module. Control modules
are used with BrakeRite SD (Severe Duty) units.

Federal law requires ALL trailers with brakes have the ability to apply
brakes in an event that the trailer becomes uncoupled from the tow
vehicle. This requires a breakaway switch and power source (battery)
on the trailer. All BrakeRite systems have circuitry for breakaway;
however, breakaway switches are provided only with SD control kits. 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 SD, 12 gauge or larger wire must be run
from tow vehicle battery to BrakeRite with a fuse or circuit breaker for
protection. Control leads for BrakeRite EHB & BrakeRite 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.
The breakaway battery serves to operate all BrakeRite models to supply
power in a breakaway condition. BrakeRite SD supplies power for both
breakaway conditions and also supplies power to operate the brake
system. All three systems have internal chargers to maintain a charge on
the battery from the tow vehicle.
Breakaway switch (circuit) i s required by law. Batteries are not included
with kits and a breakaway switch is only included in the Plug & Play kit.
When properly installed, the breakaway switch applies trailer brakes in
the event trailer becomes uncoupled from the tow vehicle. Closing the
circuit is required to activate the breakaway function. The breakaway
switch is normally an open switch held by a plastic key. A cable is
attached to a key and the tow vehicle. If units become uncoupled, the
cable pulls the key from the switch, closing the circuit and activating the
breakaway function and applying trailer brakes.
The electronic control board has a battery protection circuit to assure
breakaway battery maintains a charge at all times and prevents a surge
charge which could damage the battery. Protection is also designed into
the board to prevent power draw from both the auxiliary battery and the
tow vehicle’s electrical system.
See wiring diagrams on the next two pages.

All BrakeRite models use the same electric motor driven piston pump
and electronic controlled pressure relief valve. The exterior appearance
between them is very similar, only wires exiting housing, control board,
and distinct Model Markings are different.
Most in-cab electronic brake controllers will control brake pressure.
Brake performance is selected by the driver. Manual override can also
be applied if the driver wishes to apply only trailer brakes.

BRAKERITE SERVICE MANUAL
Electric Hydraulic Brake Actuation Systems

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Installation
The unit mounting location is at the discretion of the installer. It is
important to keep in mind protecting and servicing the unit. The
approximate physical envelope for the 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 the power unit; one set of four located on the bottom (1/4”20 UNC x 5/8” deep) and one set of three located on the 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 which can be used as a marking
and drilling diagram for custom brackets and mounting hardware. Verify
scale before use.
All BrakeRites have a 1/8”-27 NPTF port located on the lower front of
the 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. 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
a restriction in flow resulting in brakes not being able to release, poor
braking, or no brakes at all.
There are various approaches to be considered for electrical
connections depending on the brake system. Though Dexter produces
BrakeRite systems, Dexter has NO control over how towing vehicle or

trailer has been wired or it’s color coding. Therefore, when installing
any BrakeRite system, it is important that all wiring is connected per
these instructions. While it is desirable to establish a ground between
the frame, BrakeRite unit, and negative side of the 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 the front of the trailer as possible. A junction box, pin
box, or 7-way plug, are preferred starting locations. As the electrical
portion of the installation is carried out, make certain wires are
properly routed, wrapped, anchored, and protected to prevent damage,
catching road hazards, or rubbing on frame components. When making
connections in circuits, other than plug-in connectors, the 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 the installer to assure all wire are connected
properly. See Figure 1 for the preferred method for electrical wiring. This
method requires an independent battery solely for the brake system.
However, a towed vehicle auxiliary battery can be used in place of a
breakaway battery if it is in good condition and fully charged. NOTE: If
the trailer has set for an extended period of time, an auxiliary battery
may have been discharged excessively resulting in poor or no braking. If
the 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 the BrakeRite.

Figure 1: Wiring Diagram for BrakeRite EHB Actuators:

+12 Volt 40 Amp
Circuit From
Tow Vehicle
From Tow
Vehicle
Controller
(Typically Blue)

Trailer
Plug

ADAPTER
058-036-00
(IF REQUIRED)

BLACK
BLUE
WHITE

Lanyard
BROWN
VIOLET

Ground From
Tow Vehicle

VIOLET

WHITE

Breakaway
Switch

Breakaway
Battery
12 Volt
9 Amp Hour
Minimum

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BRAKERITE SERVICE MANUAL

Electric Hydraulic Brake Actuation Systems

Figure 2: Wiring Diagram for BrakeRite Plug and Play Actuators:

+12 Volt 40 Amp
Circuit From
Tow Vehicle

ADAPTER
058-036-01
(IF REQUIRED)

Trailer
Plug

From Tow
Vehicle
Controller
(Typically Blue)

Breakaway
Battery
12 Volt
9 Amp Hour
Minimum

BLACK
BLUE
WHITE

Ground From
Tow Vehicle
BROWN
VIOLET

Breakaway
Switch

Lanyard

Figure 3: Wiring Diagram for BrakeRite SD Actuators:

CONTROL MODULE
2

3

4

WHITE
BLACK

1

ADAPTER
058-036-01
(IF REQUIRED)

WHITE
BLACK

Trailer
Plug

BLACK
BLACK

Breakaway
Battery
12 Volt
9 Amp Hour
Minimum

+12 Volt 40 Amp
Circuit From
Tow Vehicle
From Tow
Vehicle
Controller
(Typically Blue)

WHITE
BLACK
BLUE

BLACK
BLUE
WHITE

Ground From
Tow Vehicle
BLACK
BLACK

Breakaway
Switch

BRAKERITE SERVICE MANUAL
Electric Hydraulic Brake Actuation Systems

Lanyard

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Function and size of five (5) wires exiting BrakeRite EBH are as follows:
ƒ White: 12 gauge, 12 VDC negative (-) system ground
ƒ Black: 12 gauge, 12 VDC positive (+) system power in
ƒ Blue: 16 gauge, Brake Control Input (from in cab electronic
brake controller)
ƒ Brown: 16 gauge, Breakaway Input (from one lead of breakaway
switch)
ƒ 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 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.

Figure 4: Most Common Factory Installed Wiring
Arrangement (Front Face of Connectors)
Trailer Cable End

Truck Plug End

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.
All air must be removed from brakes and brake lines prior to trailer
operation. To bleed brakes, remove the key from the breakaway switch
to start the unit. Starting with the brake furthest from the actuator, open
the 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. Note: While performing
the bleeding process, monitor fluid levels in the reservoir so air is not
pumped into brake lines because of low fluid. Running the BrakeRite
pump dry can damage the motor. To prevent spilling brake fluid on
the ground, place an end of plastic tubing over the end of the bleeder
screw and the other end should be placed into a container so that fluid
flow can be monitored for bubbles. After all the brakes have been bled,
replace the key in the breakaway switch.

CAUTION
Position

Color

Description

0

Yellow