Hydrastar brake actuators are widely used in automotive and marine applications for their reliability and durability. They use an electric motor to activate the hydraulic pump, which pressurizes the brake lines and applies the brakes. In this article, we will explain how to wire a Hydrastar brake actuator and provide a diagram for reference.
What You Need to Wire a Hydrastar Brake Actuator
Before you begin wiring your Hydrastar brake actuator, you will need the following:
- A Hydrastar brake actuator
- A wiring harness kit (sold separately)
- A 12V power source (battery or converter)
- A brake controller (sold separately)
- A brake switch (sold separately)
- A set of crimping tools
- A wire stripper/cutter
Step 1: Mount the Hydrastar Brake Actuator
The first step is to mount the Hydrastar brake actuator on the trailer tongue or frame. Make sure the actuator is level and secure, and the hydraulic lines are properly routed to the brakes. Refer to the installation manual for specific instructions on mounting and routing.
Step 2: Connect the Wiring Harness
Next, connect the wiring harness to the Hydrastar brake actuator. The harness should have a plug that fits into the actuator’s power port. Use the crimping tools to attach the wires from the harness to the corresponding wires on the actuator. Refer to the wiring diagram for color-coded instructions.
Step 3: Connect the Brake Controller and Brake Switch
The brake controller and brake switch are essential components of the braking system. The brake controller sends a signal to the brake actuator to apply the brakes, while the brake switch detects when the brake pedal is pressed and sends a signal to the brake controller. Connect the brake controller and brake switch to the wiring harness using the crimping tools and refer to the wiring diagram for instructions.
Step 4: Connect the Power Source
The Hydrastar brake actuator requires a 12V power source to operate. This can be a battery or a converter, depending on your setup. Connect the power source to the wiring harness using the crimping tools and refer to the wiring diagram for instructions.
Step 5: Test the Brake System
Once the wiring is complete, test the brake system to ensure it is functioning properly. Activate the brake controller and check that the brakes are responsive and not sticking. If there are any issues, refer to the troubleshooting section of the installation manual.
Hydrastar Brake Actuator Wiring Diagram
Below is a wiring diagram for the Hydrastar brake actuator. Use this as a reference when connecting the wiring harness, brake controller, brake switch, and power source. Note that the colors of the wires may vary depending on the specific model of actuator and harness kit.
| Wire Color | Function |
|---|---|
| Red | 12V Power |
| Black | Ground |
| Blue | Brake Controller Output |
| White | Brake Switch Input |
| Green | Hydraulic Pump Motor Positive |
| Brown | Hydraulic Pump Motor Negative |
Frequently Asked Questions
What Size Wire Should I Use?
The size of the wire depends on the length of the run and the amperage of the system. As a general rule, use 10-gauge wire for runs up to 15 feet, 8-gauge wire for runs up to 25 feet, and 6-gauge wire for runs up to 40 feet. Consult the installation manual for specific recommendations.
Do I Need a Fuse or Circuit Breaker?
Yes, you should always use a fuse or circuit breaker to protect the wiring and the system. The fuse or circuit breaker should be located close to the power source and sized according to the amperage of the system.
Can I Wire Two Hydrastar Brake Actuators Together?
Yes, you can wire two or more Hydrastar brake actuators together in parallel if you have multiple axles or brakes. Use a relay to control the power and make sure the wiring and fuses are sized appropriately.
Do I Need to Ground the Actuator?
Yes, the Hydrastar brake actuator should be grounded to the trailer frame or a separate ground wire. This ensures proper operation and prevents electrical issues.
What Maintenance Does the Hydrastar Brake Actuator Require?
The Hydrastar brake actuator requires regular inspection and maintenance to ensure proper operation. This includes checking the brake lines and fittings for leaks, inspecting the hydraulic fluid level and color, and cleaning the actuator and pump motor. Refer to the maintenance section of the installation manual for specific guidelines.
