Stop!!! And Consider Your Trailer Brake Options
Armed with the Pros and Cons of Various Braking Systems, Upgrade Your Trailer with the Best Brakes for the Job

By Gary Van Hall

Getting your equipment from point A to point B is all part of the job. While trailer brakes may be one of the last things you want to think about, they should be among the first things you consider when it comes to safely hauling your equipment. The fact that states are more stringently enforcing Federal Department of Transportation (DOT) safety regulations has brought trailer brake safety to the forefront.

Unlike many other types of technology, trailer brake technology has changed little until the past five to ten years. Inexpensive electric brakes have been the dominant brake system, commonly used on RVs and trailers with a gross vehicle weight (GVW) up to 26,000 lbs.

A number of events brought trailer brake technology to where it is today. The development of the electric/hydraulic actuator enabled hydraulic brakes to be used without surge brakes, putting hydraulic brakes on more equal footing with electric brakes in meeting DOT requirements. Newer hydraulic disc brakes permit enhanced braking on larger tandem and tri-axle trailers. Until recently, vacuum/hydraulic brakes had been an option for larger utility trailers. Since newer trucks no longer come equipped with vacuum systems, and vacuum add-on systems are scarce and costly, these brakes have fallen out of favor. The trend now is turning toward hydraulic disc brakes with electric/hydraulic actuators.

Larger trailers, increased load capacities and more trailer features now require improved braking systems. Knowing the ins and outs of brake technology will help you select the right trailer for the job.

Electric vs. Hydraulic Brake Debate
Both electric and hydraulic brakes offer distinct advantages and disadvantages. Electric brakes are more economical and easier to replace, at least initially.
Over time, however, they will require more maintenance than hydraulic brakes. Electric brakes have a tendency to fade and don’t function as consistently on heavy trailers. But, electric brakes can be used with any brake controller and meet DOT requirements for in-cab braking.

Hydraulic brakes require less maintenance and don’t wear out as quickly as electric brakes. They accommodate the weight requirements of larger trailers and loads and are much more tolerant of water than electric brakes.

This makes them more suitable for boat trailers. Unlike its electric counterparts, hydraulic brakes can be used with disc brakes, providing greater stopping power and less fade than drum brakes. The biggest disadvantage to a hydraulic brake system is a higher initial cost.

One major difference between the two types of brakes is their method of activation. Electric brake controllers offer both manual and automatic brake control. The brake system on the trailer is simply connected to the brake controller in the tow vehicle. Some electric brake controllers sense the braking force and activate the trailer brakes. The tow vehicle driver can activate the brake manually on any of the electric brake controllers.

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Hydraulic brakes, on the other hand, are most commonly activated using a surge brake actuator, the oldest and still most commonly used type of actuator. Surge brakes simply push brake fluid to the brakes in response to deceleration of the tow vehicle. The trailer tongue and surge mechanism push against the trailer hitch, engaging the brake.

One drawback to this braking system is that it often gives tow vehicle operators the sense of being pushed and may increase the potential to jack-knife. Because surge brakes can’t be activated from within the vehicle, it is difficult for authorities to verify that your trailer brakes work during routine safety inspections. In addition, surge brakes do not work well when backing up a trailer, especially uphill.
On steep downgrades, surge brakes can easily overheat.

The Electric/Hydraulic Actuator Solution
A much better system for activating hydraulic trailer brakes is the electric/hydraulic actuator. Mounted on the trailer, these units are activated by most standard electric brake controllers located under the dashboard of the tow vehicle. When the vehicle operator steps on the brake pedal, the controller sends an electric signal to the
actuator. This turns on an electric pump and activates a solenoid valve to proportionally send brake fluid to the brakes.

These brakes react faster than surge brakes and can generate higher pressures to create more braking power. Moreover, the electric/hydraulic actuators meet all federal DOT regulations, because a manual override permits the trailer brakes to be activated independently of the towing vehicle.

Carlisle Industrial Brake is one of industry leaders in electric/hydraulic actuators. The company’s HydraStar trailer brake actuator is available in three pressure ranges to meet the needs of drum and disk brakes from all manufacturers. Fully compliant with federal DOT braking requirements, electric/hydraulic actuators work with a wide variety of industry-standard, time-based and inertia-based electronic brake controllers. And, unlike surge actuators, electric/hydraulic actuators work in reverse and eliminate drag and push problems commonly associated with surge brakes.
Armed with the pros and cons of various braking systems, there should be no stopping you from upgrading the brake system on your trailer to ensure your equipment gets to the next job safely.

Gary Van Hall is the director of sales and marketing for Carlisle Industrial Brake and Friction, Bloomington, Ind.

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