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Hydrastar HBA-10 - Warnings; Operational Safety Warnings; Proper Installation & Sizing; Pressure & Brake Usage

Hydrastar HBA-10
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ECN 04007 Manual 440-1008 Rev D Page 2 of 10
TABLE OF CONTENTS
SECTION
PAGE
A. WARNINGS
2
B. ACTUATOR INSTALLATION INSTRUCTIONS
3
C. ELECTRICAL INSTALLATION REQUIREMENTS
4
D. TEST ELECTRICAL OPERATION
5
E. BLEEDING AND ADJUSTING THE BRAKES
6
F. TESTING & ADJUSTMENT OF ELECTRONIC CONTROLLER UNIT
7
G. REPLACEMENT PARTS LIST / MOUNTING DIMENSIONS
7
H. TROUBLE SHOOTING GUIDE
8
I. WARRANTY
10
A. WARNINGS
PROPER INSTALLATION REQUIRED - The Hydrastar™ actuator must be installed by a qualified individual.
Failure to properly install, protect, operate, and maintain the system can cause malfunction resulting in possible serious or
fatal injuries and or property damage.
MUST BE PROPERLY SIZED TO THE TOWED VEHICLE - The Hydrastar™ actuator is intended to provide
flow and pressure to the brake system on the towed vehicle in accordance with applicable state and federal laws. It is the sole
responsibility of the installer to see that the actuator is properly sized with the brake system on the towed vehicle so that the time
required to build pressure in the towed vehicle brake system is not excessive.
SELECT THE CORRECT OUTPUT PRESSURE - Over pressurizing the brakes on the trailer can cause
permanent damage to the trailer brake system. It is the sole responsibility of the installer to determine the appropriate model
of Hydrastar™ to insure that over pressurization of the trailer brake system does not occur.
NOT INTENDED TO BE USED AS A PARKING BRAKE - The Hydrastar™ actuator and trailer brakes
are intended only to supplement the service brake system on the towing vehicle. The Hydrastar™ actuator and trailer brakes
are not designed to function as a park brake. At no time should the towed vehicle brake system be used as the primary
source of braking for the towing vehicle.
REQUIRES AN IN-CAB ELECTRONIC BRAKE CONTROL – The Hydrastar™ actuator is intended to
be used with an in-cab electronic brake controller. The unit will operate with a wide variety of controllers but provides
optimum performance when used with a CTS electronic brake controller.
Contact your dealer for a list of approved brake controllers. The list is also available online at
www.cargotowingsolutions.com The in-cab controller must have an output capacity of at least 5 amps for proper operation
of the Hydrastar™ actuator.
EXTENDED STOPS CAN GENERATE EXCESSIVE HEAT - When stopped for extended periods (i.e.
such as at railroad crossings and traffic jams), apply the park brake on the towing vehicle and release the service brake pedal
so that the Hydrastar™ actuator does not run continuously. Failure to follow this guideline will cause the Hydrastar™ unit
to overheat and will damage the Hydrastar™ unit.
EMERGENCY BREAKAWAY BATTERY MUST BE CHARGED - Do not attempt to tow the towed
vehicle unless the emergency breakaway battery is fully charged.
DO NOT POWER WASH THE HYDRASTAR™ UNIT - Although the Hydrastar™ unit is weather tight, it
is not designed to withstand the direct high pressure spray from a power / car wash. Care should be taken to protect the
Hydrastar™ unit from direct spray when washing the trailer.