Suspension Electric brake failure?

pauljygrant

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Apr 1, 2015
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Hi all, tried to adjust the brakes on my Basestation today, but only 1 of the 4 was working correctly so started taking off the hubs to investigate.
shocked to find that both rear axle brakes had same issue - the magnet had broken off completely caused by failure of the magnet arm. Any ideas why the metal would snap where it locates into the magnet?
The 3rd brake is connected and located correctly and I can hear the magnet being energised (with the hub on, not sure if I can energise it with the hub off to actually see what’s happening or not happening) but not stopping the wheel despite the shoes being adjusted fairly tight. Any ideas?
 

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jazzeddie1234

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May 19, 2016
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Mandurah
That arm is fairly substantial so to have one, let alone, two break is really odd. I can't imagine an assembly mistake that would snap them off but who knows with the magnets flapping free for all or some of the time

As to part two of your question - I decided to service the brakes myself for the first time in 5 years because of ongoing poor performance and the service places telling me it was my imagination. In my case the brake magnet pivot point (under the upper spring in your photo) was seized. I freed the joint and greased and lightly greased (cue big debate) the points where the shoes touch the backing plate. Now my brakes are excellent again.

 

pauljygrant

Well-Known Member
Apr 1, 2015
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Just spent the last hour on the internet learning about the difference between standard and off-road Alko brakes and appears just to be the magnet. The standard version has the cross and fits either side, whilst the offroad version is left or right handed and a straight slot. The slot has a plastic shock absorbing material around it.
Interesting observations is that from the factory, I have standard magnets on the rear axle and offroad magnets on the front axle. Was this intentional by Jayco, or whatever they picked up from the parts bin?
Secondly, the off-road version does appear to have maintained its integrity whilst the standard magnets have probably rattled and moved too much over time causing the magnet arm to fail. Assuming this to be the case, definitely worth the extra $10 for off-road magnets even if you don’t go off-road.
 
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Drover

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Nov 7, 2013
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Thats certainly a mess, never heard that left/right hand bit before though in regards to magnets ....................
I think Alko have a great site which explains brake maintenance well ...........

With all that mess I would dismantle the whole thing, clean up the cam and the adjuster, giving the worm gear a dry lube so its working smoothly, repack bearings, when back on do up the hub nut till tight and wheel is locked then back off, adjust each brake till locked up then back off till the wheel just turns, have someone spin wheel while you pull the pin on the breaksafe, do same for each wheel then go for a bit of a drive, do the brake lock check, should skid at 40kph sort of thing back home to check hubs adjust if needed and adjust brakes that need doing ................. don't forget to replace the breaksafe pin each time either.
The spray can Brake Cleaner is good easy stuff to use, cleans things up nicely...... if using any lube use sparingly, bearing grease will spread when hot a lot so a silicon brake grease is best.

Brakes should be adjusted and bearings given a shake test after each trip and inspected once a year really....... should be a DiY job then you know what to do when stuck on the side of the road in Woop Woop........ carry grease, spanner to fit hub nut, long nose pliers, roll of paper towel and a pair of leather gloves in case things are cooking.


As an aside I discovered the difference between the 10" and 12" drums is the diameter, the shoes have the same area ......................


and I found the whys and where's of off road magnets and I think it points out why the arms could have broke off, always learning something new...... https://www.couplemate.com.au/electric-brake-parts/electric-brake-magnets-12v/
 
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Boots in Action

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Mar 13, 2017
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Ferny Grove, Queensland
Thats certainly a mess, never heard that left/right hand bit before though in regards to magnets ....................
I think Alko have a great site which explains brake maintenance well ...........

With all that mess I would dismantle the whole thing, clean up the cam and the adjuster, giving the worm gear a dry lube so its working smoothly, repack bearings, when back on do up the hub nut till tight and wheel is locked then back off, adjust each brake till locked up then back off till the wheel just turns, have someone spin wheel while you pull the pin on the breaksafe, do same for each wheel then go for a bit of a drive, do the brake lock check, should skid at 40kph sort of thing back home to check hubs adjust if needed and adjust brakes that need doing ................. don't forget to replace the breaksafe pin each time either.
The spray can Brake Cleaner is good easy stuff to use, cleans things up nicely...... if using any lube use sparingly, bearing grease will spread when hot a lot so a silicon brake grease is best.

Brakes should be adjusted and bearings given a shake test after each trip and inspected once a year really....... should be a DiY job then you know what to do when stuck on the side of the road in Woop Woop........ carry grease, spanner to fit hub nut, long nose pliers, roll of paper towel and a pair of leather gloves in case things are cooking.


As an aside I discovered the difference between the 10" and 12" drums is the diameter, the shoes have the same area ......................


and I found the whys and where's of off road magnets and I think it points out why the arms could have broke off, always learning something new...... https://www.couplemate.com.au/electric-brake-parts/electric-brake-magnets-12v/
Hi @Drover , I too had not heard of right and left brake magnets before either. My first thought was that the right and left hand backing plates were reversed, which would mean that when brake magnets are energized, they are not dragged in the direction of wheel travel, (thus pulling lever to exert pressure to expand brake shoes) but in the opposite direction which would jam the magnets against the brake shoe. With the magnet really gripping the brake drum , the forces involved would be more than enough to break off the end of the brake lever. Just a thought from "way out left field" which is easily checked as well as the primary/leading shoe being towards the front in direction of travel and the secondary (longer) shoe being towards the rear of braking system. Not the first time I have seen the brake shoes wrongly fitted and could easily be the same with the backing plates if not careful.
 

Drover

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I assume because the off road magnets have a single slot it must be to do with the alignment, angle of the dangle when on the arm, I do know the damn things are big bikkies, since I check mine out regularly I think I'll stay with the poverty magnets even though I do a big of dirt................ I have heard of the arm jamming when out of adjustment ................. of course feeling the hub at each stop lets you know if your dragging a brake or cooking a bearing before the flames start up..... it will even let you know after a big downhill run if one brake is lazy or faulty, 3 hot, burn fingers jobs and one cold as a maggot, sure sign ...... coming down out of the Snowies for example a good tyre kick walk around is a good idea, amazing what you can find and don't forget the tug....make it quick, all good get going for the air flow to cool em down more......

As always always check the wheel nuts especially if someone else has serviced it, do it before you hook up, it has been known for wheels to fall off or be discovered, usually as a knocking sound as the stud holes are getting flogged out on the rim, new nuts, new rim if your lucky........................
 

pauljygrant

Well-Known Member
Apr 1, 2015
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63
Adelaide
Dispatched my wife to a local trailer shop today for 2 new off road magnets and 2 complet backing plates with off road magnets. Now got the front axle with a pair of working brakes and hopefully shouldn’t be too difficult to fit the new backing plates to the rear wheels.
Massive variation in prices both between Alko and aftermarket parts, but also between different suppliers. Best price was $190 for a pair of offroad backing plates and highest quote was over $500 for parts only. Similarly, magnets ranged from $25 each to over $100!
Whilst overhauling the brakes, replaced the battery in the brake away controller - $27 from Bunnings.
Greased up the bearings, torqued the wheels, and almost ready for the weekend.
 

BJM

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Sep 29, 2018
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Yamba
My 2016 JOB pop top had two of the off road brake magnets on the wrong side ,plus the two front
Backing plates on the wrong sides ,must have been a bad day at Jayco.Also if leading brake shoe material not
champfered on the front edge get the file out,! Helps shoes from binding when new.
 

Boots in Action

Well-Known Member
Mar 13, 2017
1,670
1,409
113
Ferny Grove, Queensland
My 2016 JOB pop top had two of the off road brake magnets on the wrong side ,plus the two front
Backing plates on the wrong sides ,must have been a bad day at Jayco.Also if leading brake shoe material not
champfered on the front edge get the file out,! Helps shoes from binding when new.
Thanks for that info @BJM , Confirms what my earlier thoughts were in earlier post regarding backing plates on wrong sides. Some "way out of left field ideas" are closer to the truth than one thinks!!!!