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Hydrastar HBA-10 User Manual

Hydrastar HBA-10
10 pages
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ECN 04007
Manual 440-1008 Rev E
Page 1 of 10
MANUAL 440-1008
SERVICE MANUAL FOR
HYDRASTAR
HYDRAULIC TRAILER BRAKE ACTUATORS
THIS DOCUMENT TO BE USED FOR
HBA-10, HBA-12, HBA-16, MHBA-10, MHBA-12, MHBA-16
ACTUATORS
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Hydrastar HBA-10 Specifications

General IconGeneral
BrandHydrastar
ModelHBA-10
CategoryController
LanguageEnglish

Summary

Warnings

Operational Safety Warnings

Groups essential safety warnings regarding installation, sizing, pressure, usage, and maintenance.

Proper Installation & Sizing

Actuator must be installed by qualified person and properly sized for the towed vehicle.

Pressure & Brake Usage

Use correct output pressure; not for parking brake; avoid continuous running to prevent heat.

Control & Power Requirements

Requires in-cab controller (5A min); breakaway battery must be charged.

Maintenance & Cleaning

Avoid power washing; protect from debris.

Actuator Installation Instructions

Getting Started / Required Materials

Lists required materials for installation, including brake lines, hardware, fluid, and breakaway kit.

Location Considerations

Guides on choosing an optimal location for the actuator on the trailer.

Mounting Requirements

Specifies that the unit must be level, filler neck up, and requires #10 hardware.

Connecting the Brake Line

Details how to connect the trailer brake line to the actuator's 3/16" fitting.

Electrical Installation Requirements

Wire Size and Low Voltage

Critical to use correct wire size for power leads to prevent damage and void warranty.

In-Cab Controller & Connections

Requires 5A controller; ensure clean, weather-tight electrical connections.

Breakaway Battery System

Trailer needs a charged breakaway battery and switch; use proper charging method.

Test Electrical Operation

Breakaway Switch Test

Pulling the breakaway switch should activate the Hydrastar™™ unit.

Brake Pedal Test

Depressing the brake pedal should run the unit when the ignition is on.

Operational Check Note

Testing confirms operation, not proper brake function; regular inspection is needed.

Bleeding and Adjusting Brakes

Brake Bleeding Process

Step-by-step guide for bleeding actuator and trailer brakes, monitoring fluid.

Drum Brake Adjustment & Precautions

Proper drum brake adjustment is vital; protect eyes during bleeding.

Wheel Cylinder/Caliper Bleeding

Bleed farthest brakes first, ensuring clear fluid and no bubbles.

Post-Bleed Checks & Maintenance

Ensure bleeder screws are secure; re-bleed after service and check hubs.

Testing and Adjustment of Electronic Controller Unit

Controller Settings and Testing

Adjust gain/sync, test by driving and applying brakes for optimal response.

Replacement Parts and Mounting Dimensions

Parts List and Dimensions

Provides a list of available replacement parts and mounting hole dimensions.

Troubleshooting Guide

Troubleshooting Slow Brakes

Solutions include re-bleeding, drum adjustment, and checking wire size/line restrictions.

Troubleshooting Unit Operation

Checks for unit power, ground, and wiring integrity using voltage tests.

Breakaway System Troubleshooting

Tests breakaway switch function and diagnoses potential issues with the unit or controller.

Electrical Schematic

Wiring Diagram Overview

Presents a visual representation of all electrical connections for the system.

Schematic Notes and Color Coding

Explains special circuit requirements and wire color identification for various kits.

Limited Warranty and Limitation of Liability

Warranty Terms and Conditions

Outlines the two-year warranty, coverage, and notification period for defects.

Warranty Exclusions and Liability Limits

Specifies what is not covered and limits liability to the net purchase price.

Service & Replacement Parts

States warranty validity depends on servicing with genuine parts per instructions.