CAUTION – Wheels must be properly blocked to prevent the trailer and
tow vehicle from
rolling.
GETTING STARTED:
1. The following materials are required to properly install the Hydrastar™ unit:
• If your trailer is not already equipped with brake lines, you will need enough 3/16”
diameter automotive brake line to connect the trailer brakes to the Hydrastar™ unit.
(Note that ¼ “ diameter brake line will improve response time.) Where possible, steel
tubing is preferred.
• 4 pieces of #10 mounting hardware to mount the Hydrastar™ unit to the trailer
• ( 1 ) quart of DOT 3 or DOT 4 brake fluid (from a new, sealed container)
• ( 1 ) emergency breakaway kit - must include a 12 volt, 5 amp hour (minimum) battery
• Wire (see Section C. ELECTRICAL INSTALLATION REQUIREMENTS for
proper wire size)
LOCATION of the Hydrastar™ actuator is at the discretion of the vehicle owner. When
determining location, consideration should be given to the following:
1. The shorter the brake lines are between the Hydrastar™ unit and the trailer brakes, the
faster the brakes on the trailer will respond.
2. The unit should be located so that the electrical wiring and brake lines can be neatly
routed directly to the towing vehicle and trailer brakes. Special care should be taken to
minimize the number of bends and fittings in the brake line circuits.
3. An emergency breakaway kit must be located on the trailer so that the trailer breakaway
cable can be easily attached to the towing vehicle.
4. The Hydrastar™ actuator is powered from the electrical system on the tow vehicle.
In order for the Hydrastar™ unit to function properly, it must have adequat
e
electrical power. (See Section C. ELECTRICAL INSTALLATION REQUIREMENTS)
5.
The Hydrastar™ unit should not be placed in an area where it is susceptible to damage
from trailer loads, road debris, or from being stepped on. Failure to protect th
e
Hydrastar™ unit from damage can cause the unit to malfunction and void the
Hy
drastar™ warranty.
CAUTION – In stop and go traffic, the unit can get quite warm to the touch. This is normal and
should not be of concern. Care should be taken to locate the unit in an area where your skin will not come
in direct contact with the unit.
MOUNTING: Consideration should be given to the following:
1. The Hydrastar™ unit must be level, with the filler neck up.
2. It is the responsibility of the customer to provide necessary fasteners for attachment
of the Hydrastar™ actuator to the trailer. 4 pieces of #10 mounting hardware required.
CAUTION – The Hydrastar™ unit contains sensitive electronics that must be protected.
Drilling additional holes in the housing or electrostatically painting the Hydrastar™, or welding anywhere
on the Hydrastar™ unit will damage the unit making it inoperable and will void the manufacturer’s
warranty. Always remove the Hydrastar™ from the trailer before doing any welding repair or
modifications to the trailer structure.
CONNECT the brake line on the towed vehicle to the Hydrastar™ actuator.
1. Remove the red plastic plug from the brake port on the Hydrastar™ unit. This will
expose a 3/16” inverted flare fitting.
2. Brake line must be compatible with DOT 3 & DOT 4 brake fluid.
3. Flush existing brake system and lines with mineral spirits (not mineral oil), DOT 3 or
DOT 4 brake fluid prior to connecting the Hydrastar™ unit.
4. Connect the brake line from the trailer brakes to the 3/16” inverted flare fitting on the
Hydrastar™ actuator.
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