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Troubleshooting A Hydrastar Electric Over Hydraulic Braking System On 2020 Ram 5500

Question:

Recently purchased a 2021 New Horizons 5th wheel equipped with a Hydrastar 1600 brake actuator. I have my RAM OEM brake controller set to EOH Heavy. It feels like the only time the trailer brakes are applied is when I manually operate the brake controller. When I apply the brakes on the truck without manually operating the brake controller, it feels like only the truck brakes are being applied. This truck was previously used with an 2014 New Horizons 5th wheel with a different brake actuator dont recall the model, but it was goldinch colored. I read in another question that a fuse in line with the red wire should be checked? Which fuse on a RAM 5500 cab/chassis model? Can you confirm that separate wires are used to apply voltage from the controller when the truck brakes are applied vs. when the controller is manually operated? Thanks in advance for your assistance!

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Expert Reply:

I did some more research. Your OEM brake controller does not reliably work with electric over hydraulic systems, though in theory they should. In your case, you are getting an electrical signal with your brake controller and they are still not working properly. Unfortunately, their is not a definite fix for this issue if you have a Ram truck. Hydrastar suggests installing the HydraStar Electric Over Hydraulic Actuator Adapter Module for Ford and Chevy Brake Controllers, part # HBA-CAM, and test your brake controller again. If it is still not working, you most likely will have to replace it.

If that is the case, I recommend the Tekonsha Prodigy P3 Trailer Brake Controller - 1 to 4 Axles - Proportional, part # 90195, and the Tekonsha Plug-In Wiring Adapter for Electric Brake Controllers - Ram, part # 3024-P. It is a proportional brake controller that can be mounted in any orientation in your cab.

I have included product description links, a video of this brake controller being installed on a 2017 Ram 1500, and weblink to our faq about brake controllers.

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