Activated Brake Controller Installation and Operation Manual

For Customer Service and Technical Staff

Installation Instructions

Package Contents:

• 1 Brake Control Unit
• 1 Mounting Bracket
• 4 Mounting Screws
• Assorted Wire Connectors
• Cable Ties (6-10)
• 100mm Wire for Probe Type Tester

Tools Required:

• Assorted Spanners
• Drill with 1/8" Bit
• Wire Cutter/Stripper
• Nut Driver or Screwdriver

Installation Steps:

1. Mounting the Brake Controller:

   • Ensure the brake controller is installed with a 12-volt negative ground system.
   • Select a mounting location that is secure, easily reachable by the driver, and where the area behind is clear for drilling.
   • Use the bracket as a template to mark hole locations, drill holes using a 1/8" dia. bit, and secure the bracket with self-tapping screws.
   • Mount the brake control unit to the bracket with the remaining screws.

2. Wiring Connections:

   • Black Wire: Connect to Vehicle Power.
   • White Wire: Connect to Vehicle Ground.
   • Red Wire: Connect to Stop Light.
   • Blue Wire: Connect to Trailer Brakes.
   • Ensure all four wires are solidly connected. Improper wiring can damage or destroy the brake control.

3. Preliminary Adjustments:

   • With the trailer connected, press the brake pedal to display the Gain setting. Adjust to approx. 2.0 using the Gain button.
   • Press the Sync button to adjust the Sync setting to 40 as necessary.

Operating Instructions:

• Manual Override: Located on the front side, used for individual brake adjustment during initial setup or in situations where it's desirable to reduce speed slowly.
• Output (Gain) Control: Establishes the maximum power available to the trailer brakes. Adjust during setup, load changes, or to adjust for changes in road conditions.
• Sync Control: Adjusts the aggressiveness of the trailer brakes. The setting ranges from 0 (least aggressive) to 10 (most aggressive).

Test Drive and Adjustments:

• Conduct a test drive in an open area to adjust the Output (Gain) Control for firm braking without jerking or lockup.
• Adjust the Sync setting for smooth and firm stops at various speeds.
• Slight adjustments of the Output (Gain) Control may be necessary for optimal performance.

Troubleshooting:

• No Display or Decimal Point Only: Check for no power, no ground, blown circuit breaker, or incorrect wiring.
• Display Shows "OL" When Activated: Indicates an overload or short in the trailer brake circuit. Check wiring and connections.
• Weak Trailer Brakes: Increase the Output (Gain) setting or check for miswired trailer connector.
• Error "Er" Displayed: Indicates no connection between the controller and trailer brakes. Check the trailer connector and terminal positions.

Important Facts to Remember:

• Use proper gauge wire for installation to ensure efficient braking.
• Avoid routing wires near the radio antenna to reduce interference.
• Water collection in the trailer connector can reduce its lifespan.

Additional Tips:

• Light pressure on the brake pedal activates the trailer brakes without affecting the tow vehicle's brakes, useful for slowing on steep grades.
• Periodic adjustment of the Sync and Output controls may be necessary due to changing conditions or preferences.
• Operating the Manual Control may not disengage cruise control on some vehicles.

For further assistance, refer to the specific vehicle installation instructions or contact technical support.