Technical Bulletin: Electric Over Hydraulic Brake Actuator and Disc Brake Hardware Compatibility

Purpose

This bulletin provides guidance on the use of an Electric Over Hydraulic (EOH) brake actuators and disc brake hardware with the TUSON TSC-1000DISC Sway Control System.

This bulletin is intended for caravan manufacturers, trailer builders, installers, and service technicians to clarify approved components, performance requirements, and the correct application of sway control systems with hydraulic disc brake trailers.

Background

Tuson sway control systems represent leading technology in electronic trailer stability control.

Trailer sway is a lateral oscillation that may occur when towing a caravan or trailer. Uncontrolled sway can rapidly escalate, compromising tow vehicle stability and safety.

The TUSON TSC-1000DISC Sway Control System detects trailer motion using integrated sensors and applies controlled braking intervention to reduce oscillation energy and restore trailer alignment with the tow vehicle.

Operation with Electric Over Hydraulic Brake Systems

The TUSON TSC-1000DISC system operates with hydraulic disc brake trailers using Electric Over Hydraulic actuators.

During a sway event:

• The system detects the rate and direction of trailer oscillation
• A corrective braking command is issued through the brake circuit
• The EOH actuator converts the electrical signal into hydraulic brake pressure
• Controlled braking is applied to the trailer wheels
• Oscillation energy is dissipated and stable tracking is restored

The TSC-1000DISC system can operate in both symmetric and asymmetric braking configurations. The EOH actuator and system design determine which sway mitigation strategy is applied, allowing either symmetric or asymmetric braking to counteract sway.

Approved Electric Over Hydraulic Actuators

Testing by Tuson Australia has confirmed that the following 1600 PSI Electric Over Hydraulic actuators meet the performance requirements for sway mitigation:

1. FELK HydraKing 1600 PSI Electric Over Hydraulic Brake Actuator
2. HydraStar 1600 PSI Electric Over Hydraulic Brake Actuator
3. TUFFRIDE HydraTec 1600 PSI Electric Over Hydraulic Brake Actuator

These actuators demonstrated:

• Adequate hydraulic pressure generation
• Rapid response within the critical sway correction window

Approved Disc Brake Hardware

The following disc brake hardware has been tested and approved for use with the TUSON TSC-1000DISC:

• Deemax range: calipers, hubs, rotors, and associated hardware
• Tuffride range: calipers, discs, and complete disc brake systems

Note: Brake fluid selection impacts performance. DOT 4 hydraulic fluid typically responds faster than DOT 3, assisting in quicker brake actuation and improved sway mitigation response.

Application

The TUSON TSC-1000DISC system may be used with approved EOH actuators and disc brake hardware on:

• Caravans fitted with hydraulic disc brake systems
• Trailers equipped with Electric Over Hydraulic braking systems
• Installations requiring rapid brake response for electronic sway mitigation

All installation work must follow manufacturer instructions, industry best practice, and applicable Australian Design Rules (ADR).

Disclaimer

Tuson Australia has conducted testing on selected Electric Over Hydraulic brake actuators and disc brake hardware to evaluate compatibility with the TUSON   TSC-1000DISC Sway Control System.

However:

• These products are not manufactured by Tuson Australia, and Tuson does not control their design, production, or future revisions.
• Performance, reliability, or critical design changes in third-party products are entirely the responsibility of the original manufacturer.
• Tuson Australia cannot be held liable for the performance, failure, or safety of third-party components, even if previously tested.
• Compatibility must be confirmed by installers and manufacturers directly with the actuator and brake hardware manufacturer prior to installation.
• Tuson Australia cannot be held liable for any compatibility issues arising after the date of testing. Actuator manufacturers reserve the right to change their specifications, and compatibility with the Tuson TSC-1000DISC cannot be guaranteed.

Testing referenced in this bulletin was conducted independently by Tuson Australia under controlled conditions to verify performance at the time of testing only. Installation or use of any third-party component outside the tested configuration may result in unpredictable system behaviour.

Summary

The TUSON TSC-1000DISC Sway Control System:

• Operates with both symmetric and asymmetric sway mitigation, determined by the selected EOH actuator and system configuration
• Is approved for use with HydraTec, HydraKing and HydraStar EOH actuators
• Supports Deemax and Tuffride ranges of disc brake hardware
• Performs best with DOT 4 hydraulic fluid due to faster response times and a higher boiling point

When the caravan/trailer is installed with approved components and the correct hydraulic fluid, the Tuson TSC-1000DISC system provides enhanced towing stability and effective electronic sway mitigation.

Important: Use of third-party components, even if tested, is at the installer’s or manufacturer’s discretion. Tuson Australia assumes no responsibility or liability for third-party products or for any changes made by third-party manufacturers.

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