How To Convert Hydraulic Brakes To Electric Brakes

Despite the numerous steps and technical knowledge needed to convert hydraulic brakes to electric, it can be completed by a non-professional with basic hand and power tools, electrical wiring, and elbow grease. As a result of the conversion, all hydraulic lines are removed and replacedwithelectriclinesandthehydraulicbackingplatesarereplacedwithelectricones.

(Togaineasyaccesstotheundersideofthetrailer,itisadvisabletoraisethetraileronahydraulic lift so that the hydraulic lines can be removed and new electrical wiring installed. Then it will be necessarytocrawlunderneathorlayflatonyourbacktowork.)

The steps are as follows:

STEP ONE: Removethetrailer'sfourwheelssoyoucanseethehubs/drums.

STEP TWO: Theinnernutofeachhub/drumisprotectedbyadustcap. Usingawoodenorrubber mallet, tap the dust cap from different sides to remove it. For the remaining three hubs/drums, repeattheprocess.

STEP THREE: Remove all four hubs/drums by loosening the nuts securing them. The hydraulic brakebackingplateswillbevisibleoncethedustcapsareremoved.

STEP FOUR: Remove all hydraulic line connections and locate the hydraulic lines to drain brake fluid. As well as disconnecting the hydraulic lines, each backing plate must also be removed. Removing the hydraulic lines from the trailer requires dislodging them from their housings and clips.

STEP FIVE: Fourorfivenutswillbeusedtosecurethebackingplatestotheaxleflanges. Remove thebackingplatesfromtheirflangesbylooseningthenuts.

STEP SIX: Removeallbackingplatessothatthe axlesareexposed.Removedirt,grease,andgrime fromeachaxleendwithaclean,drycloth.

STEP SEVEN: Place the four electric backing plates on the table. There should be a label on each backingplateindicatingwhetherthebackingplateshouldfaceforwardorleftorright.Additionally, backingplatesmustbeorientedcorrectlywhenattachedtoaxlestoavoidpoorbrakeperformance anddamagetobrakingcomponents.

Onthebackingplatewiththe electromagnet,the horizontalsideshould be oriented downtoward theground(electricmagnetataboutsixo'clock).

STEP EIGHT: Ensure that the two leads on the back of the electric backing plate are securely attached before attaching the plate to the axle flange. Once the nuts are tightened, the leads may becomepinched.

The backing plate should be attached to the flange and all nuts should be firmly tightened. Preventing slippage or loosening may require the use of lock washers or thread sealants. There mustbeagroundwireconnectedtothechassisofthe trailer. Aringconnectorcanbeattachedto the chassis and screwed into place, with sufficient slack to handle driving's rigors. An electrical wireforthebrakesystemwillconnecttotheotherwire.

STEP NINE: Theremainingthreebackingplatesand groundingwiresshouldbeappliedaccording toStepEight.

STEP TEN: Inspectthehubsanddrumsinsideandout. Itispossibletoreusethesehubs/drumsif their inner surfaces (not the lining surfaces that contact the brake shoes) are smooth, as the electromagnetneedsasmoothmetallicsurfacetograbholdofinordertooperate.

Thelargenutshouldbetightenedaftereachhub/drumisrepositioned.Thenutshouldbeloosened slightly if the hub is not freely rotating by hand. It is important to position the dust cap carefully. The cap should not be hammered directly into place; instead, cover the cap with a block of wood beforehammeringitinplace. Eachwheelshouldbereattached.

STEP ELEVEN: Adjustingthe braketensionisthe next step. The brake tensioner can be accessed by removing the small plastic covers behind each backing plate. There will be a need for a tensioning tool. As soon as you are unable to turn the wheel by hand, tighten the tensioner. Approximatelyeighttotennotchesshouldthenbeloosened.

Followthesameprocedurefortheremainingthreewheels.

STEP TWELVE: Connectthehydrauliclinesbyrunninga10-gaugewirethroughthesameclipsand openingsusedbythehydrauliclines.

Fortrailerelectricbrakewiring,blueisthemostcommoncolor.AsshowninStepEight,connectthe mainbluewiretooneoftherearbrakeleadsusingacrimpbuttconnector.

Jumperwiresandquickspliceconnectorswillbeusedtoconnectthethreeremainingbrakestothe main blue wire (to avoid the necessity of soldering). The crimp connectors and splice connectors shouldthenbeprotectedfrommoisturebywrappingthemwithheavydutyelectricaltape.

Wiringhasbeencompletedforallbrakesandallbrakeshavebeeninstalled. Runninglights, brake lights,andturnsignallightswillbeoperationaloncethetrailerwiringisconnectedtotheelectrical brakecontrols. In terms of wiring, trailer brakesystems typically use 5 or 7-pole connectors, and thewirecolorsmaydifferdependingonthemanufacturer.

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