Level 2 · Advanced Technician · Module 13
Brake Controllers & Surge Brakes
Controller diagnosis and surge actuator service.
Lessons
- 01Controller SymptomsDexter troubleshooting chart.
- 02Surge Actuator: Fill & BleedDexter OM-A-160 procedure.
- 03Surge Hookup & BreakawaySafety chains and the breakaway lever.
- 04Controller Modulation and Brake SynchronizationDistinguish controller modulation from gain adjustment and verify coordinated braking through the prescribed road test.
- 05Electrical Measurement and Fault IsolationUse wiring requirements, voltage measurements, and series-current tests to separate controller, wiring, and magnet faults.
- 06Electric-Hydraulic Compatibility and DiagnosticsEvaluate controller compatibility, power supply, hydraulic response, and breakaway-test results on an electric-hydraulic actuator.
- 07Surge Actuator Selection and InstallationMatch the surge actuator to the brakes and hitch system while preserving its required telescoping movement.
- 08Reverse Solenoid Wiring and Profile-Specific BleedingConnect the reverse solenoid to the documented circuit and remove hydraulic air using the correct actuator-profile procedure.
- 09Hitching and Breakaway ReadinessVerify coupler engagement and distinguish a ready surge breakaway mechanism from an inadvertently applied one.
- 10Post-Service Surge Validation and Operating LimitsInterpret the prescribed surge-brake functional checks and recognize conditions that require rebleeding or additional service.
INTERACTIVE TROUBLESHOOTER
Brakes weak or not working
Step 1
Is there voltage at the magnets when the controller is applied?