Troubleshooting your HydraStar™ Brake Actuator

A simple guide to Troubleshoot your Hydrastar Brake Actuator

Please note this guide is for HydraStar™ brand Brake Actuators Only

Before starting your steps to troubleshoot your brake actuator please ensure your tow vehicle and trailer are wired correctly. 


Step 1
With the unit running and brake pressure applied, check that a minimum of 8.5 volts DC is reaching the units BLACK wire.

!! Check to see if the white ground wire runs directly to the tow vehicle ground !!
IT MUST NOT BE GROUNDED TO THE TRAILER ONLY. IT IS IMPORTANT THAT THIS GROUND WIRE RUNS DIRECTLY TO THE TOW VEHICLE’S BATTERY GROUND. NO EXCEPTIONS.


Step 2
Ensure that the ONLY wires CONNECTED to the unit are:
Blue
Black
White
Yellow (or Blue with White Striped Wires) 

Detach all other wires from the unit.
The unit should be disconnected from any other wires going to the towing vehicle, or the breakaway switch and breakaway battery. 
Failure to do this will result in a faulty test result.


Step 3
Using a 12v Battery connect the WHITE wire to the Negative (-) Terminal
Connect the BLACK wire to the Positive (+) Terminal 
The motor SHOULD NOT run
If the motor RUNS, the unit needs to be repaired.


Step 4
Leave the WHITE wire connected to the Negative (-) Terminal
Connect the BLUE and BLACK Wires Together to the Positive (+) Terminal
When connected the motor SHOULD run and the unit should pressurize
If the motor DOES NOT run, the unit needs to be repaired


Step 5
Leave the WHITE wire connected to the Negative (-) Terminal
Connect only the YELLOW (or BLUE WITH WHITE STRIPED WIRE) to the Positive (+) Terminal
When connected the motor SHOULD run and the unit should pressurize
If the motor DOES NOT run, the unit needs to be repaired


Step 6
If the previous checks are OK reconnect the wires leading to the trailer plug and repeat steps 2 through 4.
If you DO NOT get the same results as before - the problem is in the trailer wiring or electronic brake controller