AL-KO Electric Brake Troubles

I have exactly the same issue. I suspect that the wiring is not heavy enough. I had a Jayco Eagle and could not get the brakes to lock. Sold it to a relative who had a Redarc controller installed last week and presto, the brakes on that van could then be got to lock.
We have now a new van and a new tow vehicle and the brakes are just as you describe.
I'm with you - what is going on?

Yeah, I reckon you're not delivering enough volts to the brakes, high resistance somewhere.

You are measuring 'full voltage' as it enters the brakes. OK - this means that the controller and wiring are OK up to that point. I suspect that you have high resistance further down the line ie inside the brake drum. Disconnect the brake supply at each wheel and measure the resistance to earth for each drum. If they are all the same, it is probably not an electrical issue. Maybe some grease on the magnet face, or on the linings themselves.

The brakes should not earth through the drum. There is a separate earth wire from the magnet, which should be directly or indirectly earthed to the car via a wire, not just through the towball.
Regards Philip A

I had an issue with new brakes and backing plates not working very well, after replacing the controller etc I found that the magnets were not parallel to the drum face and had to bend the arm so that they made contact. Barnray

You are better off measuring the current to each wheel magnet. At maximum voltage the current should be at least 2.5A. (The resistance of a magnet is 4 Ohms.)

Can you borrow a DC clamp meter?

I have found poorly crimped connections on a relatives Jayco.

Glenn

Mate, had the same problem.
The voltage you measure is probably not at full load, so it may be misleading.
I solved my probel by chack all connections carefully. The biggest difference was when I upgrades my trailer connector (both male and female) and it was much better. Seems that was the weak link in the power getting to the brakes
CJ

HI
4 wheel electric drum , use a separate wiring loom and a dedicated trailer plug .
At least 8ga wire . Can the controller handle 4 wheel brakes ? Dumb question but some controllers can only handle single axle .
Some electric pads decrease in performance over time .

In all the electric brakes I have owned replace the drum when the magnet goes .The surface where the magnet contacts wear very badly to a rough surface .

The other point of concern is the new linnings . If the magnet surface is ok the drum needs machining . Poor drum finish can cause what ur exp.

2 ITEMS linnings need to be radius ground to suit drums [both need to be the same diameter ] . The place who machines the drums will no if u need oversize linngs .

There are leading and trailing shoes also

All this if followed adds up to a great brake job with no issues and very quick with no change in performance break in of brakes .

Swamp fox

I have had the same problem and found the earth on the patrol towbar was bad and also check all the earthing on the van! A amp check on both magnets will prove you are not drawing enough current at the magnets. It's normally an earthing problem. Michael

Hi to everyone that has replyed to me thread, that's for all the input.
What I have found was that 3 of my magnets in the drums had collapsed, replaced the magnets with new ones, would have done all 4 but was only able to obtain 3 in town today.
Brakes working fantastic again, Like brand new again.

Thanks again for all the comments & suggestions

Happy travelling

Regards,

Andrew