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Table of Contents
- 1 Table of Contents
- 2 Warnings
- 3 Actuator Installation Instructions
- 4 Electrical Installation Requirements
- 5 Test Electrical Operation
- 6 Bleeding and Adjusting the Brakes
- 7 Testing & Adjustment of Electronic Controller Unit
- 8 Replacement Parts List / Mounting Dimensions
- 9 Troubleshooting Guide
- 10 Warranty
- Download this manual
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Table of Contents
Related Manuals for Hydrastar HBA-16
Summarization of Contents
Warnings and Precautions
Proper Installation and Sizing
Ensures correct installation, sizing, and pressure for safe operation, preventing damage or injury.
Braking System Usage
Highlights that the system is not a parking brake and requires an in-cab controller for proper function.
Operational Care and Maintenance
Advises on managing heat during extended stops and avoiding power washing to protect the unit.
Actuator Installation Instructions
Installation Preparation and Materials
Lists required materials like brake lines, mounting hardware, and brake fluid for proper installation.
Actuator Location Considerations
Guidance on optimal placement for brake line length, wiring, breakaway kit, power access, and protection.
Mounting Requirements
Specifies that the unit must be level and lists required mounting hardware, warning against drilling or welding.
Brake Line Connection
Instructions for connecting the brake line to the Hydrastar actuator, including fluid compatibility and flushing lines.
Electrical Installation Requirements
Wire Size and Low Voltage Warning
Emphasizes critical wire sizing and termination for the Hydrastar unit to prevent damage and voided warranty.
In-Cab Electronic Control Requirement
States the need for an electronic brake controller with at least 5 amps output for optimal Hydrastar performance.
Electrical Connection Best Practices
Recommends clean, dry, weather-tight, and soldered connections, plus a dedicated ground.
Breakaway Battery Requirements
Details the need for a minimum 5 Ah breakaway battery, kept fully charged, and suggests a 17 Ah option.
Breakaway Battery Charging Procedure
Explains the correct method for charging the breakaway battery using a dedicated charger from the keyed accessory terminal.
Test Electrical Operation
Breakaway Switch Test
Procedure to test the unit's response when the breakaway switch is pulled and reset.
Brake Pedal Activation Test
Checks if the unit runs when the ignition is on and the brake pedal is depressed.
Bleeding and Adjusting Brakes
Brake Bleeding Procedure
Detailed steps for bleeding the Hydrastar unit and trailer brakes, emphasizing fluid level checks and wheel cylinder sequence.
Drum Brake Adjustment
Guidance on adjusting drum brakes to recommended clearances to prevent drag and damage.
Testing and Adjustment of Electronic Controller Unit
Gain and Sync Setting Adjustment
Procedure for adjusting in-cab controller gain and sync settings for optimal trailer brake response.
Replacement Parts and Mounting Dimensions
Mounting Dimensions Overview
Provides key dimensions for mounting the Hydrastar actuator, including mounting hole specifications.
Replacement Parts List
Lists part numbers for common replacement components like port adapters, bleeder caps, and breakaway battery kits.
Troubleshooting Guide
Brakes Slow to Respond
Addresses causes like incorrect bleeding, drum brake adjustment, small trailer wiring, or restrictive brake lines.
Unit Will Not Run or Shut Off
Provides diagnostic steps for wiring, power, ground connections, and component testing.
Breakaway Test Procedure
Guides on testing the breakaway system and identifying issues with the controller or the actuator's proportional valve.
Trailer Brake Aggressiveness
Solutions for brakes being too aggressive (reduce gain) or not aggressive enough (increase gain).
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