Hydrastar / Hydratec Hydraulic Electric Brake Actuator
Price
Price range: $1,150.00 through $1,495.00 Inc.GST
- Delivers up to 1,200 PSI to 1600 PSI hydraulic output pressure
- 12V DC hydraulic-electric brake actuator
- For single- or tandem-axle trailers with disc brakes
- 3/16 in hydraulic port; 11-3/4 × 3 × 7-3/8 in
Shipping
Hydrastar and Hydratec Hydraulic Electric Brake Actuators
Hydrastar hydraulic-electric brake actuator generation 7 suits boat tandem trailers from 2000kg to 4500kg.
The Hydratec actuator has a similar pedigree to Hydrastar, which is made in America.
How to Select the Correct Actuator
- 1200 PSI Actuators are ideal for trailers UP TO 3200kg
- 1600 PSI Actuators are suitable for trailers UP TO 4500kg
The brake controller controls the maximum hydraulic pressure applied to the brakes.
Both Hydrastar and Hydratec actuator pumps require a 12-volt DC Tekonsha P2 or P3 hard-wired controller. Check with your brake controller supplier for suitability.
The Tekonsha iPrimus is not compatible with Hydrastar controllers.
An electric over-hydraulic actuator requires an electric brake controller to signal the hydraulic pump actuator. Hydraulic brakes are used on boat trailers weighing over 2000kg.
Question: What type of hydraulic braking system suits the Hydrastar Actuator
Answer: The Hydrastar Actuator is ideal for controlling the following disc braking systems.
- Independent Coil Suspension Kit – Hydraulic
- 50mm Square Hydraulic Disc Brake Axle
- 60mm Round 2t – 3t Hydraulic Disc Braked Axle
- 3t Hydraulic Disc Braked Axle
Also, consider your disc pads to improve braking efficiency.
Why do I need this type of brake controller?
The Law requires trailers over 2t to be fitted with a breakaway kit.
Couplemate has a good stock of this product and ships from Brisbane.
Carlisle offers a 2-year warranty on all HydraStar units against faulty craftsmanship. Warranty issues are handled here in Australia.
Variations
- 1200 psi to suit boat trailers from 2t to 3.5t – Installation Instructions and Wiring Diagram Downloadable after Purchase.
- 1600 psi to suit boat trailers over 3.5t and up to 4.5t. Installation Instructions and Wiring Diagrams are Available for Download after Purchase.
- AL-KO IQ7 Brake Actuator – 355002E
- Hydratek Hydraulic Electric Brake Actuator
Hydrastar Actuator Specifications
- Application: single- or tandem-axle trailers with disc brakes
- Maximum output pressure: 1,200 – 1,600 psi
- Power: 12V DC
- Hydraulic port size: 3/16 inch
- Dimensions: 11-3/4 inch long x 3-inch wide x 7-3/8 inch tall
- Wire configuration:
- Black: 12-volt power
- Blue: brake controller
- Yellow: breakaway
- White: ground
- 2-Year limited warranty
What is a Breakaway Kit
A breakaway kit must apply the brakes for at least 15 minutes if the trailer disconnects from the tow vehicle.
We aim to get your purchase into the transport system, such as Australia Post or StarTrack Express, as quickly as possible.
Breakaway kits and spares are available here.
Purchase Hydrastar replacement trailer parts and spares here
- Hydrastar Circuit Board
- Hydrastar Gasket
- Replacement Cap
- Brass Hose Connectors
- Replacement Hydraulic Cylinder Cap
Couplemate recommends using a stainless-steel braided SAE hydraulic hose. A Bundy tube or a steel tube can become damaged, resulting in a loss of brake fluid flow.
SAE stands for Standard Automotive Equipment and has passed tests according to American Standards.
The braided hose is flexible and poly-coated for long-term durability. The Copper tube olive ends with short brass locking nuts.
Equipment such as Alko and Trojan disc calipers requires an olive adaptor nut with a copper washer to ensure proper sealing of hydraulic connections.
Further, the manufacturer guarantees Hydrastar 1200 and 1600 psi for two years. However, water ingress from fresh or salt water is not covered.
Finally, a stainless braided hydraulic hose is an excellent investment for connecting the Hydrastar brake actuator to the hydraulic calipers.
Hydrastar and Hydratec Installation & Care Guidelines
💡 The Do’s
- Do run the heavy white ground wire directly to the tow vehicle’s battery ground. (Never ground it only to the trailer frame.)
- Do use at least 12-gauge wire for the main power and ground connections to handle the current draw.
- Do use only high-quality D.O.T. 3 or D.O.T. 4 brake fluid as requested by your specific model manual.
- Do equip your trailer with a fully charged, minimum 5Ah emergency breakaway battery kit.
- Do mount the unit level, in a well-protected area, with the filler neck pointing straight up.
- Do check vehicle and in-cab brake controller compatibility using the official HydraStar compatibility chart.
⚠️ The Don’ts
- Don’t hold the vehicle’s service brake pedal down during extended stops (like train crossings); use the park brake instead to avoid overheating.
- Don’t ever use high-pressure power washers or car wash sprays directly on the Hydrastar unit casing.
- Don’t drill extra holes into the housing, weld the unit on, or electrostatically paint the casing—this voids the 2-year warranty.
- Don’t use standard, thin 7-core trailer cable for the primary power (black) and brake controller (blue) lines.
- Don’t splice the blue brake controller wire directly into the breakaway battery circuit.
- Don’t use mineral oil or mineral spirits to flush the final fluid lines before operation.
Frequently Asked Questions
Which Hydrastar PSI rating do I need for my trailer?
The required PSI depends primarily on your trailer’s brake setup:
- 1000 to 1200 PSI: Optimised specifically for standard trailer drum brakes.
- 1600 PSI: Engineered to provide enough pressure to fully engage disc brake calipers.
Why is the response time faster than standard surge brakes?
Unlike standard mechanical surge couplers, which require the trailer to physically push against the tow vehicle’s hitch ball to trigger braking, the Hydrastar Electric over Hydraulic (EOH) Actuator receives an instantaneous electronic signal from your in-cab brake controller the split second you press your truck pedal. This yields the industry’s fastest response time and significantly shorter overall stopping distances.
Does Hydrastar function while backing up or reversing the trailer?
Yes. One key advantage of this EOH system is that it eliminates the annoying wheel drag or lock-up common with old mechanical override brakes on downhill grades or when backing up into tight spaces.
Will my 2024 or newer GMC/Chevrolet truck work with this actuator?
While the PSI configurations remain safe for your trailer, many newer 2024+ GM factory brake controllers require a specialised Hydrastar Controller Adapter Module. This prevents the truck from accidentally disabling the trailer brake signals by default.
Additional information
| Weight | 6 kg |
|---|---|
| Dimensions | 40 × 20 × 10 cm |
| Pressure | 1200 PSI, 1600 PSI |
| Voltage | 12 Volts |
| Brake Type | Hydraulic |
| Application | Boat Trailer, Caravans, Commercial Towing |
| Axle Type | Single, Tandem |
| Model | Hydrastar, Hydratec |
Our Service Lifetime Warranty
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
Couplemate™ is a manufacturer and vendor of high-quality towing, trailer, and caravan components. Couplemate™ Core Goods and Custom Work are guaranteed to be free of defects for the service lifetime of the product when used as intended.
Warranties are non-transferrable and Couplemate™ requires satisfactory proof of purchase prior to issuing a remedy. The full Couplemate™ Warranty Policy can be found in the Terms & Conditions: Section 8 – Consumer Guarantees & Warranty.
Warranties are in addition to your rights under the Australian Consumer Law. If something is wrong with your order, please contact our team.
60-Day Returns
After 60 years of experience, we know that life has its unpredictable moments.
All Couplemate™ orders (online, over the phone, or in-store) have a 60 day period for change-of-mind returns and exchanges. There are some items that can’t be returned and some returns may incur a 15% restocking fee.
You can view our full policy for change-of-mind returns here.
Hydratec / HydraStar Hydraulic Electric Brake Actuator User Feedback
A compilation of the 4 best user reviews and technical feedback regarding electric-over-hydraulic (EOH) brake actuator performance, reliability, and installation.
User Reviews Summary
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Review 1: Instant Response Time & Shorter Stopping Distances
“Electric over hydraulic actuators provide immediate brake application with no delay, unlike surge brakes, which have a delay as the coupler collapses. This system allows drivers to control brake intensity from inside the truck with a brake controller, offering greater control.”
Review Origin: etrailer Video Review
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Review 2: Superior Stopping Power for Heavy Loads
“One of the biggest advantages of hydraulic brakes is their superior stopping power compared to standard electric brakes. Hydraulic brakes provide stronger braking force, making them ideal for heavy loads and requiring less maintenance over time.”
Review Origin: Hydrapro USA Technical Insights
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Review 3: Excellent Compatibility and Proportional Braking
“The electronic proportional pressure valve ensures that braking is smooth and effective. It features a huge reservoir which is great for multi-axle trailers with long brake lines that need high volumes of brake fluid. Intentionally activating trailer brakes when reversing works perfectly.”
Review Origin: etrailer Community Q&A
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Review 4: Modern Truck Brake Controller Integration
“Electric over hydraulic systems are great, but make sure to check compatibility with your factory in-cab controller. Newer trucks with dedicated EOH settings perform incredibly well, delivering a smooth magnetic-like simulation response without requiring aftermarket modules.”
Review Origin: The Hull Truth Boating Forum
Key Technical Takeaways
- Output Pressure: Commercial configurations range from 1,000 PSI to 1,600 PSI depending on whether the setup uses disc or drum brakes.
- Controller Settings: Always ensure the tow vehicle’s controller is properly configured to ‘EOH’ mode rather than ‘Electric-Only’ to prevent premature relay wear.
Only logged in customers who have purchased this product may leave a review.
Reviews