Tekonsha Catalogue

Transcription

Tekonsha Catalogue

Merchandising Material - Spinner Display Rack . . . . . . . . . . . . . . . . . . . . . . . . A
Proportional Brake Controls/
Prodigy®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Sentinel®, Envoy®, Voyager® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Inertia Brake Controls/
DigiTrac™II, AccuTrac® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Time-Actuated Brake Controls/
Pod®, Pilot® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Brake Control Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Brake Control Wiring Harness
7-Way Trailer Emulator
Amp Meter
Positive Ground Conversion Kit
Pulse Preventer
Brake Control Mounting Brackets / Kits
Current Monitor
Bench Tester
Electrical Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
6-Way Metal Vehicle To Trailer Connectors
4-Way Metal Vehicle To Trailer Connectors
ElectroTek® Non-Conductive Dielectric Silicone Compound
Heavy Duty Flasher
Universal Circuit Breakers
Battery Post Adapter
Battery Switches
Automatic Transmission Oil Coolers and Compression Fittings . . . . . . . . . . . A
Transmission Oil Temperature Gauge & Filter . . . . . . . . . . . . . . . . . . . . . . . . . A
Shur Set III® Breakaway Systems and Accessories . . . . . . . . . . . . . . . . . . . . . A
Shur Set III® Breakaway Systems
Battery Cases
Breakaway Switches
Cable and Pin Assemblies
Sealed Lead Acid Batteries
Battery Chargers
Magnet / Bearing Sets Reference Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Electric Trailer Brake Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
AL-KO
Dexter
Hayes
Fayette
Electric Brake Assemblies
Brake Parts Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Wheel Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
-1
-2
-3
-4
-5
-6
-7
-8
-9
- 10-11
- 12
- 13-19
- 20-21
- 22
Technical Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1-28
MERCHANDISING MATERIAL
TEKONSHA®’S SPINNER DISPLAY RACK
97000 SPINNER DISPLAY RACK
Tekonsha’s new spinner display rack maximizes product
availability while only using a minimal amount of floor
space. The revolving spinners allow complete product
viewing, provide easy access to all items and virtually
eliminate product shuffling, a frequent problem on standard shelving units. Inventory can be checked in minutes
and restocked in the half the time. The spinner display
rack is store tested to provide years of use in high traffic
areas and can easily be transferred to any section of the
store without having to remove product.
• 22 inches in diameter.
• 78 inches tall (including display sign).
• Durable steel construction with glossy black
finish.
• Adjustable spinner positions.
• Equipped with leg leveling device, ball bearing
assisted spinner rings - 4 large and 1 small, 1 catalog / brochure holder and 1 Tekonsha® sign.
• Accessories*: casters (in place of leg leveling
device), small spinner rings, large spinner rings
and bottom shelf rack.
Optional Bottom Shelf Rack
SPINNER DISPLAY PRODUCT RECOMMENDATION*
SPINNER QTY
TOP
1
2
6
6
FIRST
8
8
5
5
5
SECOND 3
3
3
3
3
PRODUCT DESCRIPTION
Tekonsha® Towing Systems Spinner Rack Sign - 97300
Tekonsha® Catalogs - 95000
Tekonsha® Brake Control Brochures - 95038
Tekonsha® Performance Brochures - 95039
Rim Clamp Nuts - 5795
Spindle Nut Kit D Type Washer - 5775
Envoy® Pivot-Mounting Kit - 5298
Universal Circuit Breakers 50 Amp - 7022A-S
Battery Post Adapter - 3194-S
Electric Trailer Magnet Kit - 6106
6-Way Car End Only Metal Connector - 62-S
6-Way Trailer End Only Metal Connector - 63-S
4-Way Trailer End Only Metal Connector - 43-S
4-Way Car End Only Metal Connector - 42-S
SPINNER QTY
THIRD
3
4
4
3
3
FOURTH 4
4
4
4
4
FIFTH
4
4
4
4
4
PRODUCT DESCRIPTION
Prodigy® Brake Control - 90185
Voyager® Brake Control - 9030
Voyager® XP Brake Control - 9035
Envoy® Brake Control - 9040
Sentinel® Brake Control - 9055
Return Spring Set - Axle Set - 5307
Dodge Brake Control Wiring Harness - 3020-P
Ford Brake Control Wiring Harness - 3035-P
GM Brake Control Wiring Harness - 3015-P
GM Brake Control Wiring Harness - 3025-P
Positive Ground Conversion Kit - 3191
Breakaway Switch - 2009-S
Breakaway Switch - 2010
Battery Charger - 2024-S
Adjusting Screw Kit - 5404
* Product and Accessories sold separately. Spinners listed from top of display to bottom.
A-1
SELF-LEVELING™ PROPORTIONAL BRAKE CONTROL
TEKONSHA®’S “SMART” CONTROL
90185 PRODIGY® Brake Control / FOR 1, 2, 3 & 4 AXLE TRAILERS
Prodigy is the latest and most intelligent brake control from
Tekonsha. This powerful control features new motion sensor technology similar to what's used in the aerospace
industry. With Prodigy no manual level adjustment is necessary, it adjusts itself to varying terrains as you drive. It is
equipped with a sensor that detects the tow vehicle's rate of
deceleration, applies proportional braking to the trailer and
features an exclusive "Boost" feature that gives users the
ability to apply more initial trailer braking power (especially
when towing heavier trailers). For backing into tough spots
this is the only inertia control that works proportionally in
reverse. A digital display depicts voltage delivery to the trailer during braking and displays continual diagnostics check
for proper connection, shorted magnet condition, open
ground and much more. A unique pocket mount allows for
flexible mounting options (optional standard mounting
bracket available). Prodigy includes a 3 ft. pigtail connector
for ease of connection when using a vehicle’s brake control
wire harness. A quick and easy disconnect feature allows
users to remove the control when not in use and store in a
supplied protective pouch. Prodigy meets National Highway
Traffic Safety Administration (NHTSA) regulations regarding
tow vehicle/trailer light activation. It also offers a limited lifetime warranty (some conditions apply). Note: Not designed
for use with electric/hydraulic trailer brake systems.
Vehicle specific brake control wire harnesses shown on
Page A-4. They now include Prodigy’s special connector.
“INCLUDED”
PRODIGY ACCESSORIES
7685 Mounting Bracket Kit-Clam
A-2
7686 Pocket Mount Kit-Boxed
7894 3 ft. Pigtail Harness Kit-Clam
I n e r t i a A c t i va t e d P ro p o r t i o n a l B r a k i n g S y s t e m s
PROPORTIONAL BRAKE CONTROLS
TEKONSHA®’S ELECTRIC TRAILER BRAKE CONTROLS
9030 VOYAGER® Brake Control / FOR 1 & 2 AXLE TRAILERS
9035 VOYAGER® XP / FOR 1, 2, 3 & 4 AXLE TRAILERS
The Voyager incorporates Tekonsha’s patented braking sensor and is
the best value you’ll find for smooth and secure trailer braking. It’s
compact size and features, like a bicolored LED brake monitor (to
assure a complete connection to trailer brakes and give an indication of
relative braking power being applied) make the Voyager extremely
versatile. Voyager minimizes interference with tow vehicle electrical
systems, uses a four wire hook up, has a broad setting range and is
compatible with most any vehicle. The Voyager XP has all the extra
power you’ll need for trailers with 3 or 4 axle trailers. The Voyager is
covered by a 5 year limited warranty from the date of consumer
purchase.
9040 ENVOY® Brake Control / FOR 1 & 2 AXLE TRAILERS
The ENVOY is built with simplicity and reliability in mind. It’s easy to
install and easier to set and use. Easily adjustable to accommodate different trailer weights. ENVOY is equipped with our patented inertia activated sensor that detects the tow vehicle’s rate of deceleration and
applies proportional braking to the trailer. New “pivot-mount” is ideal
for installation in newer model tow vehicles. Ergonomic styling
enhances functionality. Green LED monitors a secure connection with
trailer and changes to red to indicate increase of power to the trailer
brakes. Meets National Highway Traffic Safety Administration (NHTSA)
regulations regarding tow vehicle/trailer light activation. A 5 year
limited manufacturers warranty is in effect from the date of consumer
purchase. Simple four-wire hookup.
9055 SENTINEL® Brake Control/
FOR 1, 2, 3 & 4 AXLE TRAILERS
The Tekonsha Sentinel Electronic Brake Control is the result of extensive consumer focus group research. It’s ergonomic design allows for
contour installation on the dash for maximum visibility and comfortable
reach. The Sentinel uses an exclusive bicolored LED leveling system
and an easy to see power delivery display to make it the easiest inertial
brake control to set and use ever. Sentinel uses a muted green LED
(with an optional pulse mode for those whose vision may be color
impaired) to reassure the user of an uninterrupted connection to the
trailer and that the trailer brakes are actually working. Capable of
handling up to 4 braking axles, the Sentinel is covered by a 5 year
limited warranty from the date of consumer purchase.
P.O.D, AccuTrac and Pilot brake controls are shown on pages A-4 and A-5.
I n e r t i a A c t i va t e d P ro p o r t i o n a l B r a k i n g S y s t e m s
A-3
INERTIA BRAKE CONTROLS
DigiTrac™ II Electric Trailer Brake Control
AccuTrac® Electric Trailer Brake Control
AVAILABLE
SPRING 2003
80750 DIGITRAC™ II
FOR 1 TO 4 AXLE TRAILERS
80510 ACCUTRAC®
FOR 1 AND 2 AXLE TRAILERS
The new AccuPower DigiTrac II is an excellent choice for
your more demanding heavier loads and constantly changing load conditions (as in transportation of horses or livestock). DigiTrac II is able to detect the difference between a
gradual deceleration like slowing for a traffic light and the
stopping power required when braking for an unexpected
event. It’s advanced electronics and patented Inertia
Sensing System are designed for consistent and predictable
stopping power. The Inertia Sensing System uses two separate power delivery controls - one for “around town” gradual
stopping and one for urgent sudden stops. The dark, smoke
lens is ideal for direct light applications, creating optimum
visibility to read the large, two-digit display. DigiTrac II’s digital display shows voltage output to the brakes with additional protection against short circuit or loss of ground. Capable
for handling up to 4 axle trailers.
The AccuTrac is inertia activated and is for 1 or 2 axle
trailers. The AccuTrac is especially suited for constantly
changing load conditions (as in the transport of horses or
livestock). It’s advanced electronics and patented Inertia
Sensing System are designed for consistent and predictable
stopping power. The Inertia Sensing System uses two separate power delivery controls for customized stopping power
both in town and on the highway.
• Separate slide controls adjust braking action for
different towing loads
• Large easy to read dual digital display shows:
• Properly wired control
• Voltage output to brakes (vs. a percentage output)
• Connection to trailer
• Dark smoke lens ideal for direct light applications;
performs better than red lens
• Protection against short circuit and loss of ground
• Standard mounting bracket and ball mount included
• For use on any 12 volt negative ground system
• Technical support hotline 800 number
NEW• 5 year limited warranty
A-4
• Separate slide controls adjust braking action for
different towing loads
• Solid state electronics
• Easily to set-up and adjust
• Positive LED indicator confirms brake connection
• Easy-to-reach manual over-ride control
• Mounting hardware included
NEW• 5 year limited warranty
Pa t e n t e d I n e r t i a S e n s i n g S y s t e m
BASIC BRAKE CONTROLS
Pilot® Electric Trailer Brake Control
POD® Electric Trailer Brake Control
80550 PILOT®
FOR 1 TO 4 AXLE TRAILERS
80500 POD®
FOR 1 AND 2 AXLE TRAILERS
The AccuPower Pilot has just made owning and operating
a digital brake control easier than ever. The dark, smoke
lens is ideal for direct light applications, creating optimum
visibility to read the large, two-digit display. Because of the
flexible mounting options, you are able to mount the Pilot in
any direction. Our microprocessor allows you the ability to
read the display even when the Pilot is mounted upside
down. The Pilot’s digital display shows voltage output to the
brakes with additional protection against short circuit or loss
of ground. Capable for handling up to 4 axle trailers.
The POD (Power on Demand) is your best choice for 1 or
2 axle trailers ... especially when your installation options are
limited. The POD can be mounted in any direction, and its
unique design features “up-front-easy-access” adjustment
controls, even when mounted upside down. The POD is the
perfect choice for SUV’s with almost vertical dash mounting
surfaces.
• Large easy to read dual digital display shows:
• Properly wired control
• Voltage output to brakes (vs. a percentage output)
• Connection to trailer
• Dark smoke lens ideal for direct light applications;
performs better than red lens
• Microprocessor allows control to be mounted upside
down and still have a readable display
• Protection against short circuit and loss of ground
• Standard mounting bracket included with optional ball
mount available
• For use on any 12 volt negative ground system
• 3 year limited warranty
Any
Direction
Mounting
• Solid state electronics
• Power-on LED for a positive tow vehicle-to-trailer
connection
• “Up- front” manual over-ride control
• Rugged, easy mount chassis
• Mounting hardware included
• Smooth and simple installation
• 3 year limited warranty
Time-Actuated System
A-5
BRAKE CONTROL ACCESSORIES
A
B
C
D
A. B. C. D. Brake Control
O.E.M. Wiring Harness
G.
O.E.M. Style Wire Harness for models
equipped with trailer tow package. Harness
includes O.E.M. connector, 3 ft. leads
and connector for hookup to Tekonsha®
Prodigy® Brake Control (for use with
other brake controls Prodigy connector
can be removed).
Required for installation of Voyager®
9030, Voyager XP® 9035, Envoy® 9040,
Sentinel® 9055 and Prodigy® 90185
Electric Brake Controls in a Positive
Ground System Vehicle.
3191
Positive Ground
Conversion Kit-Clam Shell
A. 3015
3015-P
E
3025
3025-P
B. 3035
F
3035-P
GM Brake Control
Wiring Harness 2003
GM Brake Control
Wiring Harness 2003 Clam Shell
GM Brake Control
Wiring Harness 1999-2002
GM Brake Control
Wiring Harness 1999-2002 Clam Shell
Ford Brake Control
Ford Brake Control
Wiring Harness 1994-2003Clam Shell
Installation: It is recommended on
all F250/F350 to run a separate
ground if the factory ground is
connected to the fire-wall.
G
C. 3020
3020-P
D. 3040
H
3040-P
Dodge Brake Control
Dodge Brake Control
Toyota Brake Control
Toyota Brake Control
Available Spring 2003.
I
L
J
K
E. 7-Way Trailer Emulator
7-Way Trailer Emulator is used for the
proper installation and set-up of a brake
control when a trailer is not readily
available. Brake control set-up is
accomplished using a built-in load module
that will simulate electric magnet brakes on
a trailer. (The emulator will also check electrical continuity of all circuits in the
7-Way blade style connector.)
6560
7-Way Trailer Emulator
F. Amp Meter
M
A-6
This gauge lets you know at a glance the
amperage flow between the electronic
brake control and the electric brakes.
Complete installation instructions with wire
clip so no cutting of wires is required.
Velcro adhesive strip for easy mounting to
vehicle dash. For 1-4 axle trailers.
6700
Amp Meter-Clam Shell
Positive Ground
Conversion Kit
H. Pulse Preventer
Prevents actuation of electronic brake control by 4-way flasher circuit.
2180-S Pulse Preventer-Clam Shell
I.
Brake Control Mounting
Brackets
Replacement mounting brackets for brake
controls.
5280
Envoy 9040 and Pilot 80550
Mounting Bracket
7429
Sentinel 9055 Mounting
Bracket
J. Brake Control Mounting
Bracket Kit
Replacement mounting bracket kit for
brake controls.
2178
Voyager 9030, AccuTrac
80510 and Pod 80500
Mounting Bracket Kit
K. Pivot- Mounting Kit
Replacement pivot mount kit for Envoy
9040 and Pilot 80550. Includes pivot
mount, double sided mounting tape,
mounting screws, foam gasket and brake
control mounting screw.
5298
Envoy Pivot-Mounting
Kit-Tekonsha Clam Shell
5298-12 Pilot Pivot-Mounting
Kit-AccuPower Clam Shell
L. Current Monitor
Testing device designed to assist in
determining whether a tow vehicle’s trailer
connector has been wired properly.
Excellent diagnostic tool for installation,
setup and troubleshooting of electric trailer
brake controls. Used to level and pre-set
brake control when trailer is not available.
6565
Current Monitor
M. Bench Tester
Test device designed to determine if a
brake control is working properly. Checks
brake control output, independent of
vehicle wiring. Simulates many fault
conditions including open ground, short
circuit, open load and more.
7585
Bench Tester
ELECTRICAL ACCESSORIES
A. 6-Way Metal Connector
F. Heavy Duty Flasher
American made featuring heavy duty die
cast corrosion resistant housing. Car end
offers spring loaded cover to keep dirt and
moisture out when not in use. Coded terminals allow for easy wiring.
Interchangeable with other standard 6-way
connectors.
62
Car End Only-USA
62-S Car End Only-USA-Boxed
63
Trailer End Only-USA
63-S Trailer End Only-USA-Boxed
Replaces virtually all 12 volt, 2 terminal
flashers. 552 will flash one to four 32 C.P.
standard or long life lamps for turn signals. 552 will flash two to eight lamps for
hazard warning.
552-S
Flasher-Clam Shell
G. Universal Circuit Breakers
Long wearing; rust and corrosion resistant,
heavy duty metal. Spring loaded cover
keeps dirt and moisture out when not in
use. Positive lock prevents accidental disengagement. Interchangeable with other
popular 12 volt connectors, replace just
the parts you need. Coded terminals for
easy access and handle grips for easier
plug-in and disconnection.
42
Car End Only
42-S Car End Only-Boxed
43
Trailer End Only
43-S Trailer End Only-Boxed
Used in 6, 12, and 24V DC applications.
Automotive, R.V., air conditioners, battery
chargers, any application requiring overcurrent protection. Non-corrosive molded
cover eliminates grounding when operating against a fault line. All circuit breakers
have nuts and washers installed. Includes
mounting bracket(s).
7010A
15 Amp
7010A-S 15 Amp-ClamShell
7011A
20 Amp
7012A
30 Amp
7013A
40 Amp
7022A
50 Amp
C. Brass Terminal Screw
H. Battery Post Adapter
Not pictured. For use with 42, 43, 62, or
63 connectors.
50
Brass Terminal Screw
Battery Post Adapter for General Motors
Side Post Batteries. Provides stud for
attaching accessories wires.
3194
Battery Post Adapter
3194-S
Battery Post AdapterClamShell
B. 4-Way Metal Connector
D. Zinc-Plated Insert Screw
Not pictured. For use with the 6-Way or 4Way Metal Connectors.
51
Used with 43, 63 Connectors
52
Used with 42, 62 Connectors
E. ElectroTek®
Non-Conductive
Dielectric Silicone
Compound
ElectroTek® is to be used for all electrical connections, where a dielectric compound is
required to prevent voltage loss from arcing
and to protect contacts from corrosion.
Suppresses radio frequency interference, dissipates heat, insulates trailer wiring connectors
and seals out moisture. Effective for automotive, RV and marine electrical applications.
Non-water soluble.
3 1/2 oz. tube.
7200P ElectroTek®-ClamShell
A
B
E
F
I . Battery Switches
Battery switch is cadmium plated isolator
with terminal nuts and lock-washers.
Isolates starting battery, provides secondary battery current for auxiliary power
and full time charging of both batteries. 3
terminal switch is for metal frame grounded systems. 4 terminal switch (not pictured) has insulated ground terminal for
use with fiberglass or other nonconductive
materials.
7000
Battery Switch - 3 terminal
7000-S Battery Switch - 3 terminalBoxed
7001
Battery Switch - 4 terminal
(line drawing below)
7001-S Battery Switch - 4 terminal
(line drawing below)-Boxed
G
H
I
A-7
AUTOMATIC TRANSMISSION COOLERS
Defender® Automatic
Transmission Coolers
Stacked plate design and rugged construction make Defender Automatic Transmission
Oil Coolers nearly indestructible. Multiple
flow paths through their unique aluminum
embossed plate construction maximizes
lubrication potential and allows for faster
warmups even with cold starts. Defender has
been designed to provide maximum cooling
surface and flow volume capacity to cool
more oil in less time, making Defender coolers at least 30% more efficient than traditional tube and fin styles. A thin contour profile
makes installation easy and they carry a limited lifetime warranty.
•Multiple flow paths and a contained by-pass
system ensure maximum lubrication and stable oil flow. •Optimal oil pressure levels over
wider range of operating conditions. •Fluid
viscosity temperature control without thermostats or special valves. •100% factory
tested to withstand vibration and fluid pressure to 200 PSI. •Design specified as original
“tow package” equipment by more vehicle
manufacturers than all other coolers combined. •Limited lifetime warranty to the original owner.
NOTE: For use on vehicles with 5/16” or 3/8”
automatic transmission return lines.
See Application/Specification Chart below
for proper Transmission Cooler model
selection.
Replacement Parts:
3048-B
3049-A
4340A
4341A
5’ Hose
Fixed Steel Mounting Bracket
Mounting Kit - Fixed Steel Bracket and Nylon Ties
Nylon Tie Kit
Applications/Specifications
For Automatic Transmissions Only
Recommended Applications
To select correct cooler, determine the GCWR (Gross Combined Weight Rating) of your tow vehicle & trailer by the chart below.
Size (In.)
No. of
Heat Rejection
GCWR Rating
HxWxT
plates
BTU/HR.
(lbs.)
Cooler Kit
Number
SELF REGULATING MEDIUM DUTY MODEL
Vehicle & trailer weight 7,000 to 14,000 pounds
5 3/4 x 11 x 3/4
54
9,800
14,000
4332 SR
SELF REGULATING MODEL
Vehicle & trailer weight from 11,000 to 18,000 pounds
7 1/4 x 11 x 3/4
72
13,500
18,000
4337 SR
SELF REGULATION MODEL
Vehicle & trailer weight from 18,000 to 24,000 pounds
12 x 11 x 3/4
120
21,800
24,000
4338 SR
SELF REGULATING EXTRA HEAVY DUTY MODEL
Vehicle & trailer weight 18,000 to 28,000 pounds
12 x 11 x 1 1/2
96
24,000
28,000
4339 SR
Compression Fittings
2516 5/16” w/Hose Barb (2pcs. per kit)-Clam Shell
2538 3/8” w/Hose Barb (2pcs. per kit)-Clam Shell
3030 Radiator Fittings for Ford Vehicles (1 set per
kit, Included w/Defender Coolers)-Clam Shell
2516
A-8
2538
3030
TRANSMISSION OIL TEMPERATURE GAUGE & FILTER
4100 TFS™ Transmission Oil Temperature Gauge
4350A Defender® MagFilter
This temperature gauge lets you know at a glance the
exact transmission fluid temperature range you are operating in. Gauges are interchangeable to original equipment
and are universal for use with most transmission oil systems. TFS transmission oil gauges come with an exclusive
in-line brass tee connector, are illuminated for high visibility,
are waterproof, have an easy-to-read face, meet or exceed
all SAE specifications and include all installation hardware
and instructions.
What’s your best defense against the impurities that can
ruin your transmission? The Defender® MagFilter. It’s the
strongest little piece of protection you can buy to safeguard
your transmission fluid.
• Removes more contaminants than any other in-line filter.
Its exclusive ceramic magnet attracts and removes over
95% of metallic impurities (shavings and wear particles)
in the fluid.
• Has more dirt-holding capacity. The MagFilter’s cartridge
has an advanced paper filter element to trap nonmetallic
contaminant particles as small as 30 microns.
• Fail-safe uninterrupted fluid flow. A high capacity bypass
valve keeps the fluid moving over the magnet-even if the
paper filter becomes clogged or blocked.
• Guaranteed not to leak-ever. Inside the rugged casing, an
aviation-quality O-ring and an adhesive-strengthened
thread mean “zero leaks”, even at extreme pressures
and temperatures.
• Specially designed for simple, quick installation. The
MagFilter easily splices into the transmission return line.
Its barbed connectors mean a fast, secure fit.
• Kit includes auxiliary hose and hose clamps needed for
installation.
• Compliments all auxiliary transmission cooler installations.
• Designed for easy replacement installation at recommended automatic transmission maintenance intervals
(every 15,000-20,000 miles).
A-9
SHUR SET III® BREAKAWAY SYSTEMS AND ACCESSORIES
For optimal performance, replacement
of breakaway electrical components is
recommended every 3 to 5 years.
A
B
1026 / 1028 / 2026 / 2028 Systems & 2018 Case
A
B
20005 / 20015 Systems & 2051 Case
A
B
20010 / 20020 Systems & 20000 Case
Battery Terminals Included in systems
C
NEW
2130 Switch
Handles light to heavy towing
applications on 1 to 4 axle trailers.
A-10
A. Breakaway Systems
B. Battery Cases
For use on single, tandem,tri- and/or four
axle trailers equipped with electric brakes.
These complete systems incorporate the
highest quality components in trailer breakaway systems. Meet or exceed Department of
Transportation (DOT) specifications regarding
trailer breakaway and holding requirements.
If a breakaway occurs between your tow
vehicle and your trailer, the breakaway systems will automatically apply consistent braking power to your trailer brakes. Quick and
easy to install, the systems comes with a
weather/corrosion resistant, heavy-duty polymer case to protect the battery and charger.
Note: Refer to the Guide on the page B-23
for Breakaway Applications, Specifications
and Wiring Diagram.
Rust-proof heavy duty polymer cases protects battery and charger from elements
and corrosion.
For use on single and tandem axle trailers
equipped with electric brakes.
1026: Includes 2018 Polymer Battery Case
with A-Frame or Post Mounting Bracket;
1023 Rechargeable Sealed 12v 4-Amp/hr
Lead Acid Battery and Terminals; 2005 Nylon
Breakaway Switch.
Lead Acid Battery and Terminals; 1024 DCto-DC Accelerated Battery Charging Device
(ABCD); 2005 Nylon Breakaway Switch.
For use on single, tandem, tri- and four
axle trailers equipped with electric brakes.
(Tri- and four axle trailers require minimum
5-Amp/hr battery).
Lead Acid Battery and Terminals; 2130 Nylon
Breakaway Switch.
20005: Includes 2051 Lockable All
Polymer Battery Case with Flat Surface
Mounting; 2023 Rechargeable Sealed 12v 5Amp/hr Lead Acid Battery and Terminals;
2130 Nylon Breakaway Switch.
20010: Includes 20000 Lockable Polymer
Battery Case with Weldable Flat Surface
2130 Nylon Breakaway Switch.
Lead Acid Battery and Terminals; 2024S DCto-DC Heavy Duty Quick/Maintenance (Two
Stage) Battery Charger; 2130 Nylon
Breakaway Switch.
20015: Includes 2051 Lockable All
Polymer Battery Case with Flat Surface
2024S DC-to-DC Heavy Duty
Quick/Maintenance (Two Stage) Battery
Charger; 2130 Nylon Breakaway Switch.
20020: Includes 20000 Lockable Polymer
Battery Case with Weldable Flat Surface
2024S DC-to-DC Heavy Duty
Quick/Maintenance (Two Stage) Battery
Charger; 2130 Nylon Breakaway Switch.
Quick, easy one-bolt installation on jackpost
or A-frame – no need for cutting or drilling.
U-shaped clamp style fastener mounts over
most trailer tongues.
2018
Battery Case
Quick, easy four-bolt installation on any flat
surface. For use with self tapping screws or
similar fasteners. Lockable case.
2051
Battery Case
Quick, easy two-bolt or weldable installation
on any flat surface. Galvanized metal mounting bracket and locking bar provide secure
battery protection.
20000 Battery Case
C. Breakaway Switches
Sets trailer brakes in case of accidental
trailer breakaway. Trailer brakes are applied
automatically. 2130 has Reinforced nylon
case, Weldable metal tab, Nylon pull tab,
and is Rust and Corrosion free. Handles light
to heavy towing applications on 1 to 4 axle
trailers.
Note: Refer to page B-23 for Breakaway
Switch Wiring Diagram.
2130-B125 Breakaway Switch w/ 48” wires
2130-P
Breakaway Switch w/ 48”
wires-Clam Shell
2130-A
48” Replacement Cable &
Nylon Pin Assembly
2130-A-P 48” Replacement Cable &
Nylon Pin Assembly-Clam Shell
SHUR SET III® BREAKAWAY SYSTEMS AND ACCESSORIES
D. Breakaway Switches
G. Sealed Lead Acid Batteries
Sets trailer brakes in case of accidental trailer
breakaway. Trailer brakes are applied automatically. 2010 has Reinforced nylon case,
Weldable metal tab, Nylon pull tab, and is
Rust and Corrosion free.
2010-P
wires-Clam Shell
2010-A
Nylon Pin Assembly
Nylon Pin Assembly-Clam
Shell
12v, sealed lead acid battery for use with
Breakaway Systems on single, tandem and
tri-axle trailers equipped with electric brakes
(Tri-Axle trailers require 5-Amp/hr battery).
Battery requires periodic recharging to maintain optimum performance.
1023
4 Amp/hr Sealed Battery
2023
5 Amp/hr Sealed Battery
2023-X 5 Amp/hr Sealed Battery-Boxed
E. Breakaway Switches
breakaway. Trailer brakes are applied automatically. 2005 has Reinforced nylon case,
Nylon pull tab, and is Rust and Corrosion
free. For use with one to three axle trailers.
2005-A
Nylon Pin Assembly
F. Breakaway Switches
breakaway. Trailer brakes are applied automatically. 2009 has all Metal parts and a
Brass pull pin.
2009-P
wires-Clam Shell
2009-A
Nylon Pin Assembly
Nylon Pin Assembly-Clam
Shell
D
2010 Switch
E
H. Battery Chargers
Designed to fit securely into the Breakaway
Battery Cases. Patented temperature compensated design provides continuous recharge
for all 12v battery systems with 4-amp (minimum) output. Provides maintenance-free
assurance that breakaway batteries are always
full charged. Automatic shut-off feature will
not permit overcharge.
2024
DC-to-DC Heavy Duty
Quick/Maintenance (Two
Stage) Charger
2024-S DC-to-DC Heavy Duty
Quick/Maintenance (Two
Stage) Charger-Clam Shell
For all 12v battery systems with a 4-amp minimum output. Automatic shut-off feature that
prevents overcharging. Ideal for seasonal
storage and maintenance of recreational vehicles, motorcycles, snowmobiles, lawn tractors
and more.
2025
AC-to-DC Two Stage/
Maintenance Charger
A battery charging device designed to return
trailer breakaway system batteries (12V with
4-amp minimum output) to their maximum
potential. Patent pending.
1024
DC-to-DC Accelerated
Battery Charging Device (ABCD)Clam Shell
NEW
2005 Switch
F
2009 Switch
G
1023 Battery
G
2023 Battery
H
2024 Charger
H
2025 Charger
H
1024 Charger
Most states require breakaway switch with separate power supply when towing a trailer.
A-11
MAGNET / BEARING SETS REFERENCE GUIDE
5101-HA—White Wires
5108—Red Wires
5113—White Wires
Length
3 1/8
Width
2
Thickness
15/16
Fits or Replaces
Hayes
10 x 1 5/8
10 x 2 1/4
12 x 2
Length
3 9/16
Width
2 11/16
Thickness
7/8
Fits or Replaces
Hayes
12 x 2
Length
2 1/16
Width
1 15/16
Thickness
3/4
Fits or Replaces
Dexter
10 x 1 1/2
(All - Replaces in pairs)
(All - After Late 1994)
(Prior to late 1987)
Trailer Pac
Tow Craft
101
1103-100-006
5104—Yellow Wires (N/A)
5109—White Wires
Length
2 1/32
Width
1 31/32
Thickness
3/4
Fits or Replaces
Dexter
7 x 1 1/4
Length
3 1/8
Width
2
Thickness
15/16
Fits or Replaces
Dexter
12 x 2
Hayes
12 x 2
(Prior to April 1990)
120
1103-100-016
(After Late 1987)
Trailer Pac
Tow Craft
103
1103-100-018
5105—Red Wires
Length
3 1/4
Width
2 3/8
Thickness
7/8
Fits or Replaces
Hayes
10 x 2 1/4
(Prior to Mid 1987)
Hayes
10 x 1 5/8
(Prior to Mid 1987)
Trailer Pac
Tow Craft
100
1103-100-001
5110—White Wires (N/A)
Length
3 3/8
Width
2 7/16
Thickness
15/16
Fits or Replaces
Fayette
10 x 2 1/4
Fayette
12 x 2
Trailer Pac
108
109
Tow Craft
1103-100-005
1103-100-021
5106—Green Wires
Length
3 1/8
Width
2
Thickness
15/16
Fits or Replaces
Dexter
10 x 2 1/4
Hayes
10 x 2 1/4
5111—Red Orange Wires (N/A)
Length
3 11/16
Width
2 1/16
Thickness
1
Fits or Replaces
Hayes
12 x 2 - 4.5 K Axles
(After Mid 1987)
Hayes
10 x 1 5/8
(After Mid 1987)
Trailer Pac
Tow Craft
7 x 1 1/4
(After April 1990)
5114—Black Wires
Prior to April 1990
Trailer Pac
Tow Craft
(Prior to Mid 1988)
Dexter
Length
3 1/8
Width
2
Thickness
15/16
Fits or Replaces
Dexter
12 x 2 - 7K Axles
5118—Yellow Wires
Length
3 1/8
Width
2
Thickness
15/16
Fits or Replaces
Dexter
10 x 1 1/2
(After Mid 1988)
6106—Light Green Wires
Length
3 1/8
Width
2
Thickness
15/16
Fits or Replaces
AL-KO Kober 10 x 2 1/4
6109—White Wires
Length
3 1/8
Width
2
Thickness
15/16
Fits or Replaces
AL-KO Kober 12 x 2 6K & 7K
(Centerline)
Trailer Pac
Tow Craft
124
1103-100-023
102
1103-100-017
5112—Red Wires (N/A)
5107—White Wires (N/A)
Length
2 5/8
Width
2 5/8
Thickness
15/16
Fits or Replaces
Foreman
12 x 2
Trailer Pac
113
Tow Craft
1103-100-010
(N/A) - No Longer Available
A-12
Length
3 11/16
Width
3 1/16
Thickness
1
Fits or Replaces
Hayes 12 x 2 - 6K & 7K Axles
(Centerline)
Trailer Pac
Tow Craft
125
1103-100-022
Bearing Sets
Cup/Cone
Part No.
14276-14125A
15245-15123
25580-25520
L44610-L44643
L44610-L44649
LM48510-LM48548
LM67010-LM67048
L68149-L68111
5508
5509
5503
5501(N/A)
5502
5506
5507
5505
ELECTRIC TRAILER BRAKE REPLACEMENT PARTS
10” x 21/4”
Tekonsha
Part No. Illustration No.
Hardware
6205
6206
6106
5304
5353
5404
1
1
2
3
4
5,6
Part Name
Tekonsha
Actuating Lever — R.H.
Actuating Lever — L.H.
Magnet Kit
Return Spring Set (Axle Set)
Hold Down Kit (Axle Set)
Adjusting Screw Kit
(Spring & Screw Assembly)
Grease Seal & Cap
5604/6604
7
5651
10
Bearing Sets
5505-23
8
5502
9
Brake Shoes
6004
11
Part Name
Seal (Axle Set)
Grease Cap (Axle Set)
Bearing Set - Inner
Bearing Set - Outer
Shoe and Lining Kit
(Wheel Set)
Brake Assembly
6709
6710
Complete Assembly — L.H.
Complete Assembly — R.H.
Tekonsha
Part Name
12” x 2”
Tekonsha
Hardware
6211
6212
6109
5307
5353
5404
1
1
2
3
4
5,6
Part Name
Actuating Lever - R.H.
Actuating Lever - L.H.
Magnet Kit 6 & 7K
Single Retractor
Adjusting Screw Kit
Grease Seal & Cap
5605/6605
7
6658
10
5652
10
Bearing Sets
5503
8
5508
9
5509
9
Brake Shoes
6005
11
Brake Assembly
6713
6714
Seal (Axle Set)
Grease Cap (Axle Set) for 5508
Grease Cap (Axle Set) for 5509
Bearing Set - Inner
Bearing Set - Outer - 865 Large Bore
Bearing Set - Outer - Small Bore
Shoe and Lining Kit (Wheel Set)
A-13
Dexter
7” x 1
1/4”
Tekonsha
Part Name
Hardware
5203
5204
5104(N/A)**
5113***
5320*
5320*
5320*
5320*
Magnet Kit
Magnet Kit
Return Spring
Hold Down Clips
Adjusting Screw Spring
Adjusting Screw Assembly
1
1
2
2
3
4
5
6
Tekonsha
Grease Seal & Cap
5603
7
5651
9
Bearing Sets
5502
8
Brake Shoes
5002
10
Part Name
Seal - BTR (Axle Set)
Bearing Set - Inner & Outer
Shoe and Lining Kit
(Wheel Set)
*Contained in Hardware Kit (Axle Kit)
**5104 Prior to 4-1990
***5113 After 4-1990 to accommodate lever revision
Dexter
10” x 1
1/2”
Tekonsha
Hardware
5223 (N/A)*
5231**
5224 (N/A)*
5232**
5113*
5118**
5306
5356(N/A)
5404
1
1A
1
1A
2
2A
3
4
5,6
Part Name
Magnet Kit
Magnet Kit
Adjusting Screw Kit
Tekonsha
Grease Seal & Cap
5607
7
5651
10
Bearing Sets
5507
8
5502
9
Brake Shoes
5009
11
*Prior to Mid 1988
**After Mid 1988
A-14
Part Name
Seal (Axle Set)
Bearing Set - Inner
Bearing Set - Outer
Shoe and Lining Kit
(Wheel Set)
Dexter
10” x 2
1/4”
Tekonsha
Hardware
5209
5210
5106
5305
5353
5404
Dexter
1
1
2
3
4
5,6
Part Name
Magnet Kit
Adjusting Screw Kit
Tekonsha
Grease Seal & Cap
5604
7
5651
10
Bearing Sets
5506
8
5505
8
5502
9
Brake Shoes
5003
11
Brake Assembly
5707
5708
Part Name
Seal (Axle Set)
Bearing Set - Inner (Prior to Dec. 1983)
Bearing Set - Inner (After Dec. 1983)
Bearing Set - Outer
Shoe and Lining Kit (Wheel Set)
12” x 2”
Tekonsha
Hardware
5215
1
5216
1
5109
2
5307
3A
5305
3B
5353*
4
5404
5,6
Part Name
Magnet Kit
Single Retractor
Dual Retractor
Adjusting Screw Kit
Tekonsha
Grease Seal & Cap
5606
7
5652
10
Bearing Sets
5503
8
5507
9
Brake Shoes
5000DX
11
Brake Assembly
5711
5712
Part Name
Seal (Axle Set)
Bearing Set - Inner
Bearing Set - Outer
Shoe and Lining Kit
(Wheel Set)
*Replacement Kit Uses Coil Springs
A-15
Dexter
12” x 2” 7K
Tekonsha
Hardware
5215
5216
5114
5305
5353
5404
Hayes
1
1
2
3
4
5,6
10” x 1
Magnet Kit
Adjusting Screw Kit
A-16
1
1A
1
1A
2
2A
2B
3
4
5,6
Tekonsha
Grease Seal & Cap
5606
7
5652
10
Bearing Sets
5503
8
5508
9
5509
9
Brake Shoes
5010
11
Part Name
Seal (Axle Set)
Bearing Set - Inner
Bearing Set - Outer (865 HUB)
Bearing Set - Outer (UTG Hub)
Shoe and Lining Kit
(Wheel Set)
5/8”
Tekonsha
Hardware
5221(N/A)*
5233(N/A)**
5222(N/A)*
5234(N/A)**
5105*
5106**
5101HA***
5304
5355(N/A)
5404
Part Name
Part Name
Magnet Kit (4.5K Axles)
Magnet Kit (6K & 7K Axles)
Magnet Kit - White Wire
Adjusting Screw Kit
Tekonsha
Grease Seal & Cap
5604
7
5651
10
Bearing Sets
5507
8
5502
9
Brake Shoes
5008 (N/A)
11
Part Name
Seal (Axle Set)
Bearing Set - Inner
Bearing Set - Outer
Shoe and Lining Kit
(Wheel Set)
*Replace Lever And Use 5106 Magnet
**After Mid 1987
***After Late 1994
(N/A) – No Longer Available
Hayes
10” x 21/4”
A
Tekonsha
Hardware
5207(N/A)*
5205**
5208(N/A)*
5206**
5105*
5106**
5101HA
1
1A
1
1A
2
2A
2B
Part Name
Magnet Kit
Magnet Kit
Magnet Kit-White Wire
Late 1994
5304
3A
Single Retractor
5305****
3B
Dual Retractor
5353
4
5404
5,6
Adjusting Screw Kit
Hayes
Tekonsha
Grease Seal & Cap
5604
7
5651
10
Bearing Sets
5505***
8
5502
9
Brake Shoes
6004
11
Brake Assembly
5709-HA
5710-HA
Part Name
Seal (Axle Set)
Bearing Set - Inner
Bearing Set - Outer
Shoe and Lining Kit
(Wheel Set)
*Prior to Mid 1987
**After Mid 1987
***After 1972
****Prior to May 1977
12” x 2”
Tekonsha
Hardware
5213(N/A)*
5211**
5214(N/A)*
5212**
5108*
5109**
5101HA
1
1A
1
1A
2
2A
2B
5307
5353
5404
3
4
5,6
Part Name
Magnet Kit
Magnet Kit
Magnet Kit-White Wire
Late 1994
Adjusting Screw Kit
Tekonsha
Grease Seal & Cap
5605
7
5652
10
Bearing Sets
5503
8
5507
9
Brake Shoes
5000HA
11
Brake Assembly
5713-HA
5714-HA
Part Name
Seal (Axle Set)
Bearing Set - Inner
Bearing Set - Outer
Shoe and Lining Kit
(Wheel Set)
*Prior to Late 1987
**After Late 1987
A-17
Hayes 12” x 2” Centerline
Tekonsha
Hardware
5217(N/A)*
5218(N/A)*
5219(N/A)**
5220(N/A)**
5111(N/A)
5112(N/A)
5308(N/A)
5353-23
(N/A)
1
1
1
1
2
2
3
4
5,6
Part Name
Magnet Kit (4.5K Axles)
Magnet Kit (6K & 7K Axles)
Adjusting Screw Kit
Tekonsha
Grease Seal & Cap
5605-23
7
5652-23
10
Bearing Sets
5503
8
5507-23
9
Brake Shoes
5006(N/A)
11
5007(N/A)
11
*5217 and 5218 Prior to Mid 1984
**5219 and 5220 After Mid 1984–5220 Shown in illustration above.
Fayette
1
1
2
3
4
5,6
*Contained in Hardware Kit (Axle Kit)
**-Bonded Shoes
***After 1972
A-18
Seal (Axle Set)
Bearing Set - Inner
Bearing Set - Outer
Shoe and Lining Kit
(Wheel Set)
(4.5K and 6K Axles)
Shoe and Lining Kit
(Wheel Set)
(7K Axles)
10” x 2 1/4”
Tekonsha
Hardware
(N/A)
(N/A)
5110(N/A)
5304
5353*
5404
Part Name
Part Name
Tekonsha
Magnet Kit
Adjusting Screw Kit
Grease Seal & Cap
5604
7
5651
10
Bearing Sets
5505***
8
5502
9
Brake Shoes
5011(N/A)**
11
Part Name
Seal (Axle Set)
Bearing Set - Inner
Bearing Set - Outer
Shoe and Lining Kit
(Wheel Set)
Fayette
12” x 2”
Tekonsha
Hardware
(N/A)
(N/A)
5110(N/A)
5307
5353*
5404
Part Name
1
1
2
3
4
Magnet Kit
Adjusting Screw Kit
5,6
Tekonsha
Grease Seal & Cap
5605
7
5652
10
Bearing Sets
5503
8
5507
9
Brake Shoes
5000DX**
11
Part Name
Seal (Axle Set)
Bearing Set - Inner
Bearing Set - Outer
Shoe and Lining Kit
(Wheel Set)
*Replacement Kit Uses Coil Springs
**Bonded Shoes
Electric Brake Assemblies
5707
5708
5709-HA
5710-HA
5711
5712
5713-HA
5714-HA
6709
6710
6713
6714
10” x 2 1/4” L.H. Dexter Assembly
10” x 2 1/4” R.H. Dexter Assembly
10” x 2 1/4” L.H. Hayes Assembly
Replace in Pairs
10” x 2 1/4” R.H. Hayes Assembly
Replace in Pairs
12”x 2” L.H. Dexter Assembly
12”x 2” R.H. Dexter Assembly
12”x 2” L.H. Hayes Assembly
Replace in Pairs
12”x 2” R.H. Hayes Assembly
Replace in Pairs
10”
10”
12”
12”
x
x
x
x
2 1/4” L.H. AL-KO Assembly
2 1/4” R.H. AL-KO Assembly
2” L.H. AL-KO Assembly
2” R.H. AL-KO Assembly
Assemblies include: Backing Plate, Shoe and Linings, Magnets, Actuating
Lever, Adjusting Screw and Spring Hardware.
(Units are assembled)
Brake Assembly Mounting Bolts
5720
5721
3/8” Brake Assembly Mounting Bolt
(Used on 5 bolt mounting patterns)
7/16” Brake Assembly Mounting Bolt
(Used on 4 bolt mounting patterns)
A-19
BRAKE PARTS REFERENCE GUIDE
Shoe and Lining Kit
5000-DX
12
12
12
12
x
x
x
x
2
2
2
2
Dexter
Fayette
Aimco
Foreman
Magnet Kit
5106
10 x 2 1/4 Dexter
10 x 2 1/4 Hayes
Magnet Retaining Clip
10 x 1 5/8 Hayes
10
12
12
10
(After Mid 1987)
(New Style)
5121
(After Mid 1987)
Shoe and Lining Kit
5000-HA
12 x 2 Hayes
Magnet Kit (N/A)
5107
12 x 2 Foreman
Shoe and Lining Kit
5002
7 x 1 1/4 Dexter
Magnet Kit
5108
Shoe and Lining Kit
5003
10 x 2 1/4 Dexter
Shoe and Lining Kit
5004
5109
12 x 2 Dexter
12 x 2 Hayes
(After Late 1987)
Shoe and Lining Kit (N/A)
5006
12 x 2 Hayes
Centerline 4.5K
and 6 K
5122
(Prior to Late 1987)
Use 6004
2 1/4 Dexter
2 Dexter
2-7K Dexter
2 1/4 Hayes
5007
12 x 2 Hayes
Centerline 7K
5008
10 x 1 5/8 Hayes
Axle Set
5009
10 x 1 1/2 Dexter
Axle Set
5110
10 x 2 1/4 Fayette
12 x 2 Fayette
7 x 1 1/4 Dexter
5011
5111
10 x 2 1/4 Hayes
12 x 2 Hayes 4.5 K
Centerline
6004
10 x 2 1/4 AL-KO
10 x 2 1/4 Hayes
Shoe and Lining Kit
6005
12 x 2 AL-KO
10 x 2 1/4 Hayes
5112
12 x 2 Hayes 7K
Centerline
5113
(All - Replaces in pairs)
(All - After late 1994)
(Prior to Mid 1988)
7 x 1 1/4 Dexter
(Prior to 4-1990)
5207
10 x 2 1/4 Hayes
Magnet Kit
Lever - R.H. (N/A)
5221
10 x 1 5/8 Hayes
Lever - L.H. (N/A)
5222
5208
10 x 2 1/4 Hayes
5118
(Prior to Mid 1987)
(Prior to Mid 1988)
Magnet Kit
6106
5209
10 x 2 1/4 Dexter
5210
10 x 2 1/4 Dexter
10 x 1 1/2 Dexter
(After Mid 1988)
6109
Lever - R.H.
5211
Lever - L.H. (N/A)
5224
(After Late 1987)
5212
12 x 2 Al-KO
6K & 7K
12 x 2 Hayes
(After Late 1987)
Lever - R.H. (N/A)
5213
10 x 1 5/8 Hayes
10 x 2 1/4 Hayes
(Old Style)
12 x 2 Hayes
(Old Style)
12 x 2 Hayes
(Prior to Mid 1988)
Lever - R.H.
5231
10 x 1 1/2 Dexter
(After Mid 1988)
Lever - L.H.
5232
Lever - R.H. (N/A)
5233
10 x 1 5/8 Hayes
(After Mid 1987)
Lever - L.H. (N/A)
5234
12 x 2 Hayes
10 x 1 1/2 Dexter
(After Mid 1988)
Lever - L.H. (N/A)
5214
10 x 1 1/2 Dexter
12 x 2 Hayes
10 x 2 1/4 AL-KO
Magnet Retaining Ring
10 x 1 5/8 Hayes
Lever - R.H. (N/A)
5223
10 x 1 1/2 Dexter
Lever - L.H.
10 x 1 5/8 Hayes
(After Mid 1987)
Lever - R.H.
6205
10 x 2 1/4 AL-KO
Lever - L.H.
(Prior to Mid 1987)
6206
10 x 1 5/8 Hayes
A-20
(After Mid 1984)
(Prior to Mid 1987)
12 x 2-7K Dexter
Magnet Kit
12 x 2 Hayes
Centerline
Lever - L.H. (N/A)
Lever - R.H.
10 x 2 1/4 Hayes
(Prior to Mid 1987)
5220
(After April 1990)
Magnet Kit
5105
Lever - L.H. (N/A)
(Prior to Mid 1987)
7 x 1 1/4 Dexter
5120
Magnet Kit (N/A)
5104
10 x 1 1/2 Dexter
12 x 2 Hayes
Centerline
(After Mid 1984)
Magnet Kit
Magnet Kit
10 x 1 5/8 Hayes
10 x 2 1/4 Hayes
12 x 2 Hayes
5101-HA
5219
Lever - R.H. (N/A)
Lever - L.H.
Magnet Kit
Lever - R.H. (N/A)
Lever - L.H.
5206
12 x 2 Hayes
Centerline
(Prior to Mid 1984)
Magnet Kit (N/A)
10 x 2 1/4 Fayette 5114
Shoe and Lining Kit
5218
Magnet Kit (N/A)
12 x 2 Dexter 7K
Lever - L.H. (N/A)
7 x 1 1/4 Dexter
Lever - R.H.
5205
12 x 2 Hayes
Centerline
(Prior to Mid 1984)
10 x 1 1/2 Dexter
10 x 2 1/4 Dexter
12 x 2 Dexter
Lever - L.H.
5204
12 x 2 Dexter
5217
Magnet Kit (N/A)
Shoe and Lining Kit
5010
5216
Lever - R.H. (N/A)
(Prior to Mid 1987)
Shoe and Lining Kit
Lever - L.H.
Lever - R.H.
5203
12 x 2 Dexter
(New Style)
(After Mid 1987)
5215
12 x 2 Hayes
(After Mid 1987)
Lever - R.H.
Wire Clip
12 x 2 Hayes
Magnet Kit
x
x
x
x
10 x 2 1/4 AL-KO
BRAKE PARTS REFERENCE GUIDE
Lever - R.H.
6211
12 x 2 AL-KO
Adjusting Screw Kit
5404
Lever - L.H.
6212
12 x 2 AL-KO
Return Spring (Axle Set)
5304
10 x 2 1/4 AL-KO
10 x 1 5/8 Hayes
10 x 2 1/4 Hayes
(Single Ret.)
10 x 2 1/4 Fayette
10 x 2 1/4 AL-KO
10 x 1 5/8 Hayes
10 x 1 1/2 Dexter
10 x 2 1/4 Hayes
10 x 2 1/4 Dexter
10 x 2 1/4 Fayette
10 x 2 1/4 Aimco
12 x 2 AL-KO
12 x 2 Hayes
12 x 2 Dexter
12 x 2 Fayette
12 x 2 Aimco
12 x 2 Foreman
Bearing Set (L68149 Cup
L68111 Cone)
5505
10 x 2 1/4 Hayes
(Dual Ret.-Prior to
May 1977)
(After 1972)
(After 1972)
10 x 2 1/4 Dexter (In)
10 x 2 1/4 Dexter
10 x 2 1/4 Aimco
10 x 2 1/4 Foreman
12 x 2 Aimco
12 x 2 Dexter
Use 5404
Grease Cap
Bearing Set (LM48510 Cup
LM48548 Cone)
5506
5407
(Dual Ret.)
12 x 2 Foreman
5306
10 x 1 1/2 Dexter
10 x 1 5/8 Hayes
10 x 1 1/2 Dexter
10 x 2 1/4 Hayes
10 x 2 1/4 Dexter
10 x 2 1/4 Fayette
10 x 2 1/4 Aimco
12 x 2 Hayes
12 x 2 Dexter
12 x 2 Fayette
5307
12 x 2 AL-KO
12 x 2 Hayes
12 x 2 Dexter
(Single Ret.)
12 x 2 Fayette
Return Spring (Axle Set) (N/A)
5308
12 x 2 Hayes
Centerline
Adjusting Slot Plug
5410
(Prior Dec. 1983)
(In & Out)
7 1/4 x 1 1/4 Foreman
(In & Out)
7 x 1 1/4 Dexter BTL
7 x 1 1/4 Dexter
5353
10 x 2 1/4 AL-KO
10 x 2 1/4 Hayes
10 x 2 1/4 Dexter
10 x 2 1/4 Fayette
10 x 2 1/4 Aimco
12 x 2 AL-KO
12 x 2 Hayes
12 x 2 Hayes
Centerline
12 x 2 Dexter
12 x 2 Fayette
Hold Down Kit (Axle Set) N/A)
5355
10 x 1 5/8 Hayes
Hold Down Kit (Axle Set) (N/A)
5356
10 x 1 1/2 Dexter
5507
5508
5509
(In & Out)
7 1/4 x 1 1/4 Fayette
(In & Out)
10 x 1 5/8 Hayes (Out)
10 x 1 1/2 Dexter (Out)
10 x 2 1/4 Hayes (Out)
10 x 2 1/4 Dexter (Out)
10 x 2 1/4 Fayette (Out)
10 x 2 1/4 Foreman (Out)
Bearing Set (25580 Cup
25520 Cone)
5503
12 x 2 AL-KO (In)
12 x 2 Hayes (In)
12 x 2 Dexter (In)
12 x 2 Fayette (In)
12 x 2 Foreman (In)
12 x 2 AL-KO (In)
6 & 8 Hole
12 x 2 Dexter
6K & 7K
865 Hub (Out)
12 x 2 AL-KO
8 Hole
865 Hub (Out)
15123 Cone)
10 x 2 1/4 AL-KO (Out)
7 x 1 1/4 Dexter BTR
7 1/4 x 1 1/4 Foreman
12 x 2 AL-KO
(Large Bore)
Brake Assembly - L.H.
5707
10 x 2 1/4 Dexter
Brake Assembly - R.H.
5708
10 x 2 1/4 Dexter
14125A Cone)
(In & Out)
(In & Out)
10 x 1 5/8 Hayes (In)
12 x 2 Hayes (Out)
12 x 2 Dexter (Out)
12 x 2 Fayette (Out)
12 x 2 Foreman (Out)
12 x 2 AL-KO
12 x 2 Hayes
12 x 2 Dexter
12 x 2 Fayette
12 x 2 Foreman
Grease Cap
6658
Bearing Set (LM67010 Cup
LM 67048 Cone)
Bearing Set (L44610 Cup
L44649 Cone)
Hardware Kit (Axle Set)
5320
(Prior 1972)
All Systems
5502 7 1/4 x 1 1/4 Hayes
5652
10 x 2 1/4 Foreman (In)
10 x 2 1/4 Fayette (In)
12 x 2 Hayes
Centerline
Adjusting Screw Spring Set
10 x 2 1/4 AL-KO
10 x 1 5/8 Hayes
10 x 1 1/2 Dexter
10 x 2 1/4 Hayes
10 x 2 1/4 Dexter
10 x 2 1/4 Fayette
10 x 2 1/4 Foreman
(After Dec. 1983)
Adjusting Screw Kit (N/A)
5406
5651
10 x 2 1/4 AL-KO (In)
10 x 2 1/4 Fayette (In)
10 x 2 1/4 Hayes (In)
5305
Grease Cap
12 x 2 Dexter
6 K & 7K
UTG Hub (Out)
12 x 2 AL-KO
6 & 8 Hole
(865 Small)
Seal
7 1/4 x 1 1/4 Hayes
7 x 1 1/4 (BTR)
10 x 1 5/8 Hayes
10 x 2 1/4 Hayes
10 x 2 1/4 Dexter
10 x 2 1/4 Fayette
5605
12 x 2 Hayes
12 x 2 Fayette
5606
12 x 2 AL-KO
12 x 2 Dexter
5607
10 x 1 1/2 Dexter
6604/5604 10 x 2 1/4 AL-KO
6605/5605 12 x 2 AL-KO*
5602
5603
5604
*5709-HA 10 x 2 1/4 Hayes
*5710-HA 10 x 2 1/4 Hayes
5711
12 x 2 Dexter
5712
12 x 2 Dexter
*5713-HA 12 x 2 Hayes
Brake Assembly- R.H.
*5714-HA 12 x 2 Hayes
6709
10 x 2 1/4 AL-KO
6710
10 x 2 1/4 AL-KO
6713
12 x 2 AL-KO
6714
12 x 2 AL-KO
Brake Assembly Mounting Bolts
5720 3/8” 5 Bolt Mounting Pattern
5721 7/16” 4 Bolt Mounting Pattern
*(Replace in pairs)
A-21
WHEEL HARDWARE
A
A. Rim Clamps
B
B. Rim Clamp Bolts
C
Rim clamps are used with demountable
hub and drums on mobile home type rims.
Note: Rim clamp bolt and rim clamp nut
also required.
5790
Rim Clamps-Set of 5Clam Shell
Rim clamp bolts are used with demountable hub and drums on mobile home type
rims. Note: Rim clamp and rim clamp nut
also required.
5791
Rim Clamp Bolts(1/2 - 20 x 1 7/8”)Set of 5-Clam Shell
5792
5793
C. Rim Clamp Nuts
D
E
Rim clamp nuts are used with demountable hub and drums on mobile home type
rims. Note: Rim clamp and rim clamp bolt
also required.
5794
Rim Clamp Nuts(1/2 - 13)-Set of 5Clam Shell
5795
Rim Clamp Nuts(1/2 - 20)-Set of 5Clam Shell
D. Spindle Nut Kits Standard Washer
Secures brake hardware on spindle axles.
5774
Spindle Nut KitStandard Washer(1” - 14 Spindle)Clam Shell
F
G
E. Spindle Nut Kits D Type Washer
Secures brake hardware on spindle axles.
5775
Spindle Nut KitD Type Washer(1” - 14 Spindle)Clam Shell
F. Wheel Nuts
Secures wheel to brake drum.
5780
13/16 Wheel Nut (1/2 - 20)-Set of 5Clam Shell
H
G. Wheel Bolts
Secures wheel to brake drum.
5787
Wheel Bolt-(1/2 - 20)Set of 5-Clam Shell
H. Bearing Protector
5511
A-22
1.980 Bearing Protector
Set of 2-Clam Shell
NOTES
A-23
Technical
Brake Control Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Control Instructions
Prodigy® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sentinel® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Envoy® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voyager® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AccuTrac® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pod® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Control Wire Harness Wiring Chart . . . . . . . . . . . . . . . . . . . .
Trailer Emulator Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amp Meter Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positive Ground Conversion Kit Instructions . . . . . . . . . . . . . . . . .
Pulse Preventer Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breakaway Systems Applications/Specifications/Wiring Diagram . .
Shur Set III® Installation and Battery Data . . . . . . . . . . . . . . . . . . .
Connector Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Trailer Brake Part Identification . . . . . . . . . . . . . . . . . . . . .
Bearing Protector Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Switch Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B - 2-3
B - 4-6
B - 7-8
B - 9-10
B - 11-12
B - 13-14
B - 15-16
B - 17
B - 18
B - 19
B - 20
B - 21
B - 22
B - 23
B - 24
B - 25
B - 26
B - 27
B - 28
Brake Control Instructions for DigiTrac™II will be available Spring
2003. To request a copy visit our website at www.tekonsha.com or
contact your Sales Representative.
Technical
B-1
BRAKE CONTROL WIRING INSTRUCTIONS
Wiring Instructions for Electronic Brake Controls
Read and follow all instructions carefully before
wiring brake control. Keep these instructions
with the brake control for future reference.
BLACK Wire (Positive Battery)
WHITE Wire (Negative Battery)
RED Wire (cold side of stoplight switch)
Generic Wiring Diagram
BLUE Wire (brake output to trailer)
E
1. Using the appropriate hardware, connect the
WHITE (-) wire to the NEGATIVE (-) terminal
of the battery.
F
A
B
D
C
A.
B.
C.
D.
E.
F.
G.
Brake Control
12 Volt Battery
Chassis Ground
Trailer Connector
Stoplight Switch
Automatic Reset Circuit Breaker
Turn / Brake Lights
Important Facts to Remember
1. The brake control must be installed with a 12
volt negative ground system. (To install with a
positive ground system use Tekonsha Towing
Systems P/N 3191)
2. Reversing BLACK and WHITE wires or
improper wiring will damage or destroy brake
control.
3. Be sure to solidly connect all four wires or
brake control will not function properly.
4. Soldering is recommended or crimp-on butt
connectors are a suitable substitution.
5. Route all wires as far from the radio antenna
as possible to reduce AM interference.
6. Use of proper gauge wire when installing the
brake control is CRITICAL, smaller gauge wire
may result in less than efficient braking.
Minimum wire gauges are as follows:
• 1-2 axle applications – 14 GA.
• 3-4 axle applications – 12 GA.
7. Collection of water inside the trailer connector
mounted on the tow vehicle will reduce the
life of the connector. To minimize corrosion
build up inside the connector:
8. Connector terminals should be completely
covered with dielectric compound (Tekonsha
Towing Systems P/N 7200)
9. Mount trailer connector such that the brake
line and ground terminals are not located
near the 6 o’clock position.
10.Technical Assistance Call Toll-Free:
1-888-785-5832 or www.tekonsha.com
Generic Wiring Instructions
NOTE: Please review your vehicle’s
Specific Wiring Section before continuing
with the following Generic Instructions.
NOTE: Grounding to any other location
than the negative terminal of the battery may
cause intermittent braking or lack of sufficient
voltage to trailer brakes. DO NOT ground the
WHITE wire to the dash or other interior metal
surfaces.
2. Connect BLACK (+) wire through an automatic reset circuit breaker (20 amp for 1-2
axles, 30 amp for 3-4 axles) to the POSITIVE
(+) terminal of the battery. The BLACK wire
is the power supply line to the brake control.
3. The RED (stoplight) wire must be connected
to the cold side of the brake pedal stoplight
switch. Splice down line from the switch, DO
NOT disturb the position of the switch.
4. The BLUE (brake output) wire must be connected to the trailer connector’s brake wire.
Specific Wiring Instructions for
Daimler Chrysler Tow Vehicles
NOTE:
1. For all Dodge tow vehicles equipped with the
Factory Tow Package Brake Connector, the
15 amp fused power line will not be
sufficient for 3 and 4 axle applications. For
3 and 4 axle applications, a separate power
wire directly connected to the POSITIVE
(+) terminal of the battery with a 30 amp
automatic reset circuit breaker inline is
required to be connected to the BLACK (+)
wire of the brake control.
1988-1993 D and W Series:
The brake control’s RED (stoplight) wire splices
into the WHITE wire on the cold side of stoplight
switch.
1994-1995 D and W Series and
1995-1996 Ram Van:
into the WHITE WITH TAN TRACER wire on the
cold side of the stoplight switch.
1996-1999 Dodge Ram / Dakota and
1999 Durango:
The factory Tow Package has a 4 pin connector
located on the steering column under the dash.
Follow factory supplied wiring instructions.
1988-1990 Jeep:
into the LIGHT BLUE WITH BLACK TRACER wire
on the cold side of the stoplight switch.
1991-1993 Jeep:
into the WHITE WITH TAN TRACER wire on the
cold side of the stoplight switch.
1994 and Newer Jeep:
Consult Jeep Dealer.
FORD Tow Vehicles
NOTE:
1. Prior to 1992, the Ford Trailer Tow Package
DOES NOT include the stoplight wire which
the brake control’s RED (stoplight) wire
splices into.
2. For all Ford tow vehicles equipped with the
Factory Tow Package Brake Connector, the
20 amp fused power line will not be sufficient for 3 and 4 axle applications. For 3
and 4 axle applications, a separate power
wire directly connected to the POSITIVE
(+) terminal of the battery with a 30 amp
automatic reset circuit breaker inline is
required to be connected the BLACK (+)
wire of the brake control.
Explorer, Ranger and Aerostars:
into the cold side of the stoplight switch
1989 – 1991 E and F Series:
The brake control’s RED (stoplight) wire must
splice into the stoplight line via the turn signal
harness. The turn signal harness is a crescent
shaped connector attached to the steering column. The connector has two rows with four positions on the inner row and seven positions on
outer row. The wire, which needs to be spliced
into, is LIGHT GREEN in color and is located at
the second position of the outer row of seven.
1992-1993 E and F Series:
into the Ford 4-pin connector’s LIGHT GREEN
wire for F Series or LIGHT GREEN WITH RED
TRACE for E Series. The connector is located at
the bottom of the instrument panel, directly
below the radio, for F Series, and near the brake
pedal support arm for E Series.
1994-1999 E and F Series &
1997-1999 Expeditions and Navigators
into the Ford 6-pin connector’s LIGHT GREEN
wire. The connector is attached to the computer
module access located just right of the steering
column.
1999 F250-F350:
The 6 pin connector is located behind the fuse
panel just under the steering column (C).
1. Remove fuse panel (D), just to the right of the
opening is a vertical panel and a 6-pin connector (A).
2. There is an access hole (B) the lower right
corner of this panel. Feed the connector,
Technical
Wiring Legend
READ THIS FIRST:
B-2
BRAKE CONTROL WIRING INSTRUCTIONS
Wiring Instructions for Electronic Brake Controls (continued)
supplied with your Tow Package, through this
hole and up to the fixed connector mounted
on panel.
3. Connect the brake control’s wires to the
connector’s pigtail following Tow Package
Instructions.
C
A
•Multiple wires wrapped with YELLOW tape.
(DO NOT DISTURB, AIR BAG SENSOR WIRES)
4. Probe the 4 light gauge wires with a test light.
5. The wire that is cold until brake pedal is
depressed and does not flash with hazard
flashers activated is the correct wire. Splice
that wire into the brake control’s RED (stoplight) wire.
6. Rewrap remaining wires.
• Pull off cover, look at the large cavities at the
top.
• The second cavity (A) from the left will be the
6-pin connector for electronic trailer brakes.
A
Old Style Convenience Center
B
D
GM Tow Vehicles
1988-1993 S, T, C, K and G Series
1994 S, T and Suburban Series
into the WHITE wire on the cold side of the stoplight switch.
1994 C, K and G Series
into the YELLOW wire on the cold side of the stoplight switch.
1995-1996 All GM Tow Vehicles
into a specific WHITE wire on a 10-pin connector.
This connector is located to the left of the steering
column. It is coming from the main loom of wires
going into the instrument panel. The connector
is WHITE and is wrapped with gray foam tape, it
will have two WHITE wires exiting the connector.
The correct wire is the WHITE wire located in corner (F position) of the connector. Splicing into
this specific wire will eliminate any problems with
electrical circuits associated with ABS or the
cruise control.
1997 GM Full Size Trucks
1. Locate the convenience center at the firewall
just under the emergency brake pedal.
2. Remove 6-8” of tape covering main loom of
40+ wires.
3. You will find:
•5 WHITE Wires
•4 light gauge wires (16 GA.)
•1 heavy gauge wire (14 GA.)
A
1998-1999 GM Truck, Suburban, and Tahoe
1. Locate the convenience center at the firewall
just under the emergency brake pedal.
2. At the bottom of the convenience center locate
the bottom row of cavities marked:
•DRK GRN (Rectangular Shaped)
•NAT (Square Shaped)
3. Inside the small square cavity (NAT) are two
male spade terminals. The spade terminal on
the right is the Stoplight Feed (A).
4. Connect an INSULATED 1/8” female spade
terminal to the brake control’s RED (stoplight) wire.
5. Connect the female spade terminal to the
male terminal specified in STEP 3.
1999 Silverado and Sierra Trucks
GM provided a 6-pin connector for an electronic
brake control for the following trim levels:
•LS in late 1999 model year production.
•LT for all 1999 model year production.
To see if your truck has this new 6-pin connector,
see image below (New Style Convenience
Center).
New Style Convenience Center
• Find convenience center at the lower left side
of the firewall inside the cab.
• Remove the cover by unscrewing the large
black nut in the center of the cover.
If your truck:
• DOES NOT have this style of convenience center, see instructions for 1998-1999 GM Truck,
Suburban, and Tahoe.
• DOES have this style of convenience center,
see instructions below for 1999 New Style
Convenience Center.
1999 New Style Convenience Center
• WITHOUT Trailer Tow Package
This connector will be available on all models
without trailer tow option. However, the only
wires that are useable at the connector end will be
the stoplight (RED) and ground (WHITE). The 12
volt power line (BLACK) and electric trailer brake
(BLUE) will terminate just under the vacuum
assist outside the firewall. Therefore, the BLACK
and BLUE wires will have to be run to the battery
(BLACK) and trailer connector (BLUE). The mating 6-pin connector is available from GM (P/N
12171982) or Tekonsha Towing Systems (P/N
3025) that will interface with the 6-pin connector
in the convenience center. Once again this connector will not be fully functional until power
(BLACK) is run to the positive side of the battery
through an automatic reset circuit breaker, and
the electric trailer brake (BLUE) is connected to
the trailer connector at the rear of the vehicle.
These wires can be found under the vacuum
assist in the engine compartment.
• WITH Trailer Tow Package
All vehicles with trailer tow option will have a mating 6-pin connector located in the glove box.
Connect the brake control to the mating connector following GM instructions included with the
connector.
Technical
P/N 4399 Rev G
B-3
®
PRODIGY INSTRUCTIONS
Instructions for Prodigy Brake Control
For 2, 4, 6 and 8 brake applications
READ THIS FIRST:
installing or operating the Prodigy. Keep these
instructions with the brake control for future
reference.
Components of the Brake Control
A. Power Knob
B. Boost Button
C. Manual Knob
D. Connector (For Wiring Harness)
E. Mounting Hole (1 per side)
Installation Guide
NOTE: The Prodigy must be mounted from 0
degrees to 70 degrees nose up. (See Below).
In hilly terrain it is advisable to leave a margin
at either extent to keep bars from coming on
when going up and down hills. When mounted
near level the lower bars may come on during
heavy acceleration (see Trouble-shooting
Chart). This will not affect the performance
during braking.
Failure to install the Prodigy within these constraints may cause impaired performance.
Option 1:
Use Pigtail Wiring Harness included. This harness can be installed by following the Generic
Wiring Guide.
2.
CAUTION Reversing the connection to a
breakaway battery on the trailer will destroy
the Prodigy.
3.
CAUTION Disconnect trailer plug from the
tow vehicle prior to testing a breakaway
switch or you may destroy the Prodigy.
Display Readings after Wiring the Prodigy
After successfully wiring your Prodigy you should
see the following on the two-digit display:
Do not mount or activate RF generating
items (cell phones, two way radios) near
(less than 12") the brake control.
4. The Prodigy employs an inertial sensor. It
senses deceleration and generates an output
that is based on deceleration, thus the term
“Proportional Braking”.
5. The Prodigy will “HOLD” your trailer with
25% of power setting while you are at a
standstill with brake pedal applied for longer
than 5 seconds.
6. The Prodigy will brake proportionally in reverse.
It will apply the appropriate brake voltage
based on deceleration.
• Power to Prodigy without trailer connected.
Displays for 15
seconds then
changes to:
• Power to Prodigy with trailer connected and
Boost
Boost
feature
feature
not
engaged.
engaged.
WARNING The Gross Combined Weight Rating
(GCWR) must never exceed the vehicle manufacturers recommendation.
9.
CAUTION This control is not designed for use
with electric-hydraulic trailer brake systems.
Traditional Bracket Mount
A. Mounting Bracket
B. #8 X 3/8" Machine Screw with Internal Tooth
Washer
NOTE: Drilling or use of longer screws may
damage unit.
1. Securely mount bracket to a solid surface.
2. Insert supplied #8 x 3/8" machine screws
on each side into the mounting holes.
3. Adjust control to desired position and tighten
screws until snug.
Under Dash Pocket Mount
• Manual Knob Activated without trailer
7. For Technical Assistance and Warranty
Information call: 1-888-785-5832 or
www.tekonsha.com
8.
Mounting the Prodigy
Wiring Brake Control
Your Prodigy brake control has a new and unique
connector located at the back of the control. This
connector allows you two options to wire your
brake control.
Option 2:
Use a Ford, Dodge or GM specific wiring harness.
If your vehicle came with a factory tow package
that included a 7-way connector, you can purchase a Tekonsha OEM wiring harness with the
Prodigy connector on one end and your specific
vehicle's connector on the other. See Generic
Wiring Guide, for location of your vehicle's connector.
1.
• Power to Prodigy but display is in power-saving mode (no motion or activity for at least
fifteen minutes).
• Manual knob activated (with trailer), 5.4
denotes a hypothetical power output. This
value is set using the power knob. Range is
0.0 to 13 volts. This is an indication of voltage output to electric brakes.
C
Technical
Electronic Brake Control
A. Pocket Mount
B. #6 X 1/2" Self Tapping Screw
C. Pocket Mount Template
B-4
®
1. Securely mount Pocket Mount to a solid surface using supplied #6 X 1/2" Self Tapping
Screws.
2. Insert Prodigy Brake control.
3. Plug in connector.
NOTE:
1. Front of the Prodigy must be horizontal,
see below.
2. The Prodigy must be parallel to direction of
travel, see below.
Correct
Incorrect
1. Connect trailer to tow vehicle.
Boost On
2. With engine running hold manual full left
and set Power Knob to indicate 6.0.
indicating Boost On by the right most decimal.
3. Drive tow vehicle and trailer on a dry level
paved surface at 25 mph and fully apply
manual knob.
For example: With the boost off, [ .c ], during a
braking event, the power to the brakes starts out at
zero and increases with deceleration. With the
boost on level 1, [ b.I ], during a braking event,
the power automatically starts out at approximately
13% of the power setting and increases with deceleration. With the boost on level 2, [ b.2 ] or with
boost on level 3, [ b.3 ], during a braking event,
the power automatically starts out at approximately
25% of the power setting and increases with deceleration.
Some cases where you might want to use the boost
button:
✓ If trailer brakes lock up:
❑ Turn power down using power knob.
✓ If braking was not sufficient:
❑ Turn power up using power knob.
4. Repeat Step (3) until power has been set to a
point just below wheel lock up or at a sufficient force as to achieve maximum braking
power.
5. Using the brake pedal, make a few low speed
stops to check the power setting. Trailer
braking is initiated and terminated via the
stoplight switch. When the brake pedal is
released, trailer braking will cease.
• You like the trailer braking to ‘LEAD’ the tow
vehicle’s braking
• Towing a full vs. empty trailer
• Degraded brake performance (most electric
brakes require manual adjustment - see
Appendix A or a dealer for adjustment or repair)
Boost Setting
D i r e c t i o n o f Tr ave l
D i r e c t i o n o f Trave l
Automatic Leveling of the Sensor
The Prodigy will automatically acquire the proper
level setting. It will also automatically adjust as
you travel up or down hills.
Adjusting the Power to the Trailer
Brakes (Prior to setting Boost)
Once the control has been securely mounted
within the 0 to 70-degree range, it is necessary to
set the power needed to stop the trailer during a
braking event.
The boost button was designed to allow a more
aggressive setting for your trailer brakes and is available in three levels - [ b.I ], [ b.2 ], [ b.3 ]. Each
incremental boost setting increases the sensitivity of
the Prodigy’s inertial sensor, enhancing the participation of the trailer brakes during a braking event.
The first press on the boost button displays the current setting. Boost is advanced to the next level by
continuing to press the boost button.
NOTE: Boost not intended to be used to take
place of trailer brake adjustment or repair.
See the chart below for recommended “Boost” settings (indicated with X) for typical Trailer to Vehicle
weight relationships.
Select your boost setting based on your towing situation, driving preference and condition of your trailer
brakes.
Five seconds after setting the boost level, the display
will show
Ty p i c a l B o o s t S e t t i n g s F o r O p t i m a l P e r f o r m a n c e
(with properly adjusted trailer brakes*)
TRAILER WEIGHT compared to VEHICLE WEIGHT
Trailer weighs LESS than Vehicle
Trailer weighs APPROXIMATELY SAME as Vehicle
Technical
Trailer weighs UP TO 25% MORE than Vehicle
BOOST “OFF”
➮
INCREASING BOOST LEVEL
X
X
X
X
X
X
X
X
X
X
Trailer weighs UP TO 40% MORE than Vehicle
WARNING Do not exceed Gross
Trailer weighs OVER 40% MORE than Vehicle
Combined Weight Rating (GCWR)
* Increased Boost setting may be needed if trailer brakes are worn, see Appendix A or a dealer for brake adjustment or repair.
B-5
X
➮
®
NOTE:
1.
2.
3.
Always warm the trailer's brakes before setting the power. Warm trailer brakes tend to be more responsive than cold brakes. To warm
trailer brakes, drive a short distance (1/4 mile) at 45 MPH with manual lever engaged approximately halfway.
WARNING The power should never be set high enough to cause
trailer brakes to lock up. Skidding trailer wheels can cause loss of
directional stability of trailer and tow vehicle.
4.
Not all trailer brakes will lock up due to various conditions. However,
inability to lock up the brakes generally indicates the need for an
inspection to determine the cause.
5.
When the power is set correctly you should feel unified braking
between the trailer and tow vehicle.
6.
WARNING Boost setting will be cleared under abnormally low battery conditions. Check boost setting after starting vehicle.
The power may need to be adjusted for different load weights and
road conditions.
Reverse
(Reverse continued)
(If “boost” was active, the right hand decimal point will also be on.) After
three minutes the “BOOST” and “HOLD” features will automatically return
to your previous settings.
When backing a trailer you can cancel “BOOST” and “HOLD” for a period of
three minutes. This can be accomplished by pressing the boost button continuously for five seconds with the brake pedal depressed. The display will
indicate:
NOTE:
Returning to your previous settings prior to three minutes can be accomplished by pressing the boost button.
Troubleshooting Chart
Display
Situation
Probable Cause
Flashes 2 times a second or a
steady display.
Trailer is connected and Prodigy loses
connection to battery ground.
Flashes 2 times per second.
Prodigy “sees” an overload condition during operation.
Flashes 2 times per second.
1. Brake wire sees short during idle condition.
2. Use of some test lights or non-Tekonsha testers
can cause this problem.
The lower two bars flash
Prodigy is mounted at too low an angle.
The upper two bars flash
Prodigy is mounted at too high an angle.
Flashes for 15 seconds
1.
2.
3.
4.
No display with manual or pedal
activation.
1. Loss of power to Prodigy.
2. Loss of ground to Prodigy.
No display until activation
Prodigy is in power-saving mode due to no motion for fifteen minutes.
No braking
Power control set to 0.
Trailer not connected to tow vehicle.
Trailer connected with open circuit on brake line.
Trailer connector disconnected or corroded.
Loss of trailer brake magnet ground.
Power interruption while brake pedal
is depressed.
Appendix A: Trailer Brake Adjustment**
Brakes should be adjusted (1) after the first 200 miles of
operation when the brake shoes and drums have “seated,” (2) at 3000 mile intervals,
(3) or as use and performance requires. The brakes should be adjusted in the following manner:
Note: With drop spindle axles, a modified adjusting tool with about an 80
degree angle should be used.
1. Jack up trailer and secure on adequate capacity jack stands. Follow trailer manufacturers recommendations for lifting and supporting the unit. Check that the
wheel and drum rotate freely.
5. Replace the adjusting hole cover and lower the wheel to the ground.
2. Remove the adjusting hole cover from the adjusting slot on the bottom of the
brake backing plate.
3. With a screwdriver or standard adjusting tool, rotate the starwheel of the adjuster
assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn.
6. Repeat the above procedure on all brakes.
CAUTION Never crawl under your trailer unless it is resting on properly placed jack stands.
Follow the trailer manufacturers recommendations for lifting and supporting the unit.
Do not lift or place supports on any part of the suspension system.
**Note: Trailer Brake Adjustment procedures courtesy Dexter Axle.
Technical
CAUTION Do not lift or support trailer on any part of the axle or the
suspension system.
4. Then rotate the starwheel in the opposite direction until the wheel turns freely
with a slight lining drag.
P/N 7689 Rev F
B-6
®
SENTINEL INSTRUCTIONS
Instructions for Sentinel Brake Control
For 2, 4, 6 and 8 brake applications
B
READ THIS FIRST: Read and follow all
A
instructions carefully before installing or operating the brake control. Keep these instructions
with the brake control for future reference.
F D
G
C
Adjusting the Power to the
Trailer Brakes
A. Mounting Bracket
B. #6 x 3/8” Screws
NOTE: Drilling or use of longer screws may
damage unit.
A
E
A.
B.
C.
D.
E.
F.
G.
B
Power Knob
Manual Slide Knob
Bracket Mounting Holes
Bi-Colored Level Indicator Light
Level Knob
Red Power Display Lights
Green Diagnostic Light
1. Do not mount or activate RF generating items
(cell phones, two way radios) near (less than
12”) the brake control.
2. Reversing the connection to a breakaway
battery on the trailer will destroy the brake
control.
3. Disconnect trailer plug from the tow vehicle
prior to testing a breakaway switch, or you
may destroy the brake control.
4. The level adjustment is CRITICAL. The level
adjustment determines whether automatic
braking response is delayed or aggressive.
5. This brake control is activated by inertia. It
that reflects the inertia sensed. In a stationary state, the brake control will not apply the
trailer brakes unless the Manual Slide Knob is
actuated.
www.tekonsha.com
Installation Guide
NOTE: The Brake Control must be mounted
from 20 degrees to 90 degrees nose up. Failure
to install brake control within these constraints
may cause your control to become inoperable.
Technical
90°
20°
B-7
2. Insert supplied #6 x 3/8” screws on each
side into the mounting holes.
screws until snug.
Before Wiring the Brake Control
5. Once the brake control has been leveled such
that the Bi-Colored Level Indicator Light
shows GREEN, release the foot pedal.
An optional blinking GREEN Diagnostic Light verses a constant GREEN light to monitor positive
trailer connection is a set up option. This option
was made available for people who may have difficulty distinguishing between red and green lights.
To activate this option:
1. Engage manual slide knob and hold.
2. Connect power to the brake control. The
GREEN diagnostic light will now blink at a rate
of once every eight (8) seconds. When the
trailer is connected. Troubleshooting diagnostics will also cause this light to blink at a much
faster rate – refer to Trouble Shooting Chart.
Leveling the Sensor
After the brake control has been securely mounted the level adjustment must be set.
NOTE:
1. This brake control is activated by inertia and
requires the level to be set properly, or the braking response will be too harsh or ineffective.
2. To properly level the sensor, the tow vehicle must
be parked on a level surface, it is not necessary to
connect a trailer to level sensor.
3. Due to the fine tuning ability of the inertia level
adjustment, the level knob can be turned up to
ten complete rotations from stop to stop.
1. Set power knob to maximum by fully rotating
upward until three bars show on knob.
2. Depress tow vehicle’s brake pedal and hold.
3. Rotate the Level Knob counter-clockwise until
the Bi-Colored Level Indicator Light starts to
change colors from RED to GREEN.
4. Slowly rotate the Level Knob clockwise until
RED color just shows, and then carefully
turn the Level Knob back counter-clockwise
until the solid GREEN color is just visible.
NOTE: When the brake control is leveled
properly there will be very little current flowing
through the brake magnets in a static state with
the foot pedal depressed. The brake magnets
will hum when there is current flowing through
them. Anytime the Bi-Colored Light shows any
color other than GREEN, there is current flowing through the brake magnets.
Once the control has been installed and properly
leveled, it is necessary to set the power needed to
stop the trailer during a braking event.
2. Set Power Knob to mid position (2 bars showing).
paved surface at 25 mph and apply manual
slide knob.
(Rotate power knob down).
(Rotate power up).
point just below wheel lock up or at a sufficient
force as to achieve maximum braking power.
stops to check the Power and Level adjustments.
The automatic response (brake pedal) is initiated and terminated via the stoplight switch.
When the brake pedal is released, trailer braking will cease.
Fine Tuning
Now that the Power has been set, it is time to fine
tune the level setting for the majority of the
stopping that you will be doing.
1. Make several slow (25 MPH) stops as if coming up to a stop sign and take notice of how
the trailer brakes respond:
✓ Brakes Grab Too Much
❑ You have an Aggressive Setting:
To correct this condition rotate level
knob counter clockwise.
✓ Trailer Tending to Push Tow Vehicle
❑ You have a Delayed Setting:
knob to clockwise.
2. Repeat until desired trailer braking is achieved.
3. When the Manual Slide Knob or Brake Pedal is
activated Bi-Colored Level Indicator Light shows:
✓ CLEAR – you have a delayed setting.
✓ GREEN – you have a typical setting.
✓ RED – you have an aggressive setting.
NOTE:
1. Always warm the trailer’s brakes before setting the power. Warm trailer brakes tend to
be more responsive than cold brakes. To
warm trailer brakes, drive a short distance
(1/4 mile) at 45 MPH with manual slide
engaged approximately halfway.
2. The power should never be at a level high
enough to cause trailer brakes to lock up.
Skidding trailer wheels can cause loss of
3. The power may need to be adjusted for different load weights and road conditions.
4. Not all trailer brakes will lock up due to various conditions.
®
SENTINEL INSTRUCTIONS
5. When the level and power are set correctly
you should feel unified braking between the
trailer and tow vehicle.
6. Braking performance may be slightly sluggish in sub-freezing temperatures. Allow
adequate time for the brake control to warm
prior to use in sub-freezing temperatures.
7. When in doubt of the proper setting procedures review the above steps starting at LEVELING THE SENSOR through FINE TUNING
or consult your tow card included with your
brake control.
Sentinel Normal Operation Chart
Light Code
Dim GREEN diagnostic light.
GREEN diagnostic light, glowing dim to bright.
RED lights begin to glow.
GREEN diagnostic light flashes at 8 second interval.
Condition
Trailer connected, system is working.
Start of braking action.
Increased current to trailer brakes.
Trailer connected, system is working. (Optional Set-Up)
Sentinel Troubleshooting Chart
All lights flash rapidly with Manual Slide Knob or Brake
Pedal activated.
No GREEN diagnostic light.
Bi-Colored Level Indicator light is OFF with Manual
Slide Knob activated.
Bi-Colored Level Indicator light is OFF with Brake
Pedal activated.
1.
2.
3.
4.
5.
1.
Probable Cause
Direct short or excessive current request.
Use of some test lights or non-Tekonsha testers can cause this problem.
Low battery voltage on tow vehicle.
Direct short, excessive current request or poor ground connection to
tow vehicle's battery. (TRAILER BRAKES ARE INOPERABLE)
Trailer not connected to tow vehicle.
Trailer connected with open circuit on brake line.
Trailer connector corroded.
Loss of trailer brake magnet ground.
Loss of Brake Control ground (WHITE wire)
Power Knob is set at minimum.
1.
2.
3.
4.
5.
6.
7.
Power Knob is set at minimum.
Level not set properly.
Brake Control is mounted out of range, nose too far down. Less than 20º
Level not set properly.
Brake Control is mounted out of range, nose is greater than 90º.
Bad connection on RED wire
Blown stoplight fuse.
1.
2.
3.
1.
Braking with foot pedal is delayed.
1. Level adjustment is set delayed, rotate clockwise until
bi-color light is just turning RED.
Braking with foot pedal is aggressive.
1. Level adjustment is set aggressive, rotate counter-clockwise
until bi-color light is just turning GREEN.
Technical
Situation
GREEN diagnostic light flashes at 3 times per second.
P/N 7449 Rev M
B-8
®
ENVOY INSTRUCTIONS
Instructions for Envoy Brake Control
dash using other side of double sided tape.
3. Using Mounting Ball (B) as a template, drill
(3) 1/16” holes for a #6 screw size.
4. Secure Mounting Ball (B) to dash using (3)
#6 x 3/8” screws supplied.
5. Insert Mounting Screw (D) through bottom of
brake control.
6. Place Foam Gasket (C) on top of brake control inserting Mounting Screw (D) through
small hole.
7. Attach brake control to Mounting Ball.
8. Rotate brake control to desired position and
For 2, 4 and 6* brake applications
70°
READ THIS FIRST:
installing or operating the brake control. Keep
these instructions with the brake control for
future reference.
E
NOTE:
0°
A
1. Front of brake control must be horizontal,
see below.
2. Brake control must be parallel to direction
of travel (A), see below.
Installation Guide
D
C
A.
B.
C.
D.
E.
F.
G.
B
F
Power Knob
Manual Slide Knob
Bi-Colored Light
Ball Mount Interface
Level Knob
Mounting Screw Hole
Technical
B-9
2. Reversing the connection to a breakaway battery on the trailer will destroy the brake control.
4. The light is:
• GREEN when trailer is connected
• RED when brake pedal or manual is activated and trailer is connected.
5. The GREEN light draws 5 milliamperes of current from tow vehicle. It would take over
10,000 hours to drain the tow vehicle battery.
actuated.
www.tekonsha.com
NOTE:
A
G
The Brake Control must be mounted
from 0 degrees to 70 degrees nose up. (See Below).
Failure to install brake control within these constraints may cause your control to become inoperable.
tighten until snug.
B
A
A
Correct
Incorrect
A. Mounting Bracket
NOTE:
Drilling or use of longer screws may
damage unit.
2. Insert supplied #6 x 3/8”screws on each side
into the mounting holes.
screws until snug.
A
B
C
Leveling the Sensor
NOTE:
D
Under Dash Ball Mount
A. Double Sided Tape
B. Mounting Ball
C. Foam Gasket
NOTE:
1. Arrow on top of Mounting Ball must point
toward rear of tow vehicle, as shown above.
2. Prior to mounting, clean dash with
all-purpose cleaner or 50/50 water alcohol
mixture.
D. Mounting Screw
1. Attach double sided tape (A) to top of
Mounting Ball (B).
2. Temporarily attach Mounting Ball (B) to
1. Due to the fine tuning capability of the inertia level adjustment, the level knob can be
fully rotated 8-9 times from stop to stop.
This equals roughly 45 partial turns across
the finger indent on the bottom of the
control.
2. This brake control is activated by inertia and
requires the level to be set properly, or the
braking response will be too harsh or
ineffective.
3. To properly level the sensor, the trailer and
tow vehicle must be parked on a level surface and trailer must be connected to tow
vehicle.
4. The brake control has been shipped from
the factory with the level knob adjusted to
the maximum counter-clockwise position.
Therefore, the level knob will only rotate
clockwise from the factory shipped position.
®
ENVOY INSTRUCTIONS
A
NOTE:
B
C
D (-)
E (+)
When the brake control is leveled
Trailer Brakes
A.
B.
C.
D.
E.
F.
Power Knob
Bi-Colored Light
Manual Slide Knob
DELAYED (Clockwise)
AGGRESSIVE (Counter-Clockwise)
Level Knob
1. Connect trailer to tow vehicle, Bi-Colored Light
(B) should glow GREEN.
2. Set Power Knob (A) to maximum. (Rotated
fully clockwise)
3. Depress tow vehicles brake pedal and hold.
(Bi-Colored Light (B) should glow bright RED)
4. Rotate the Level Knob (E) to the left (clockwise-Delayed) until the Bi-Colored Light (B)
starts to change colors from RED to GREEN.
NOTE:
You may need to partially rotate level
knob as many as 45 times depending upon your
mounting angle.
5. Carefully rotate the Level Knob (E) to the
right (Counter-Clockwise – Aggressive) until a
shade of ORANGE is visible.
Bi-Colored Light should show:
• DIM ORANGE for a typical setting.
• BRIGHT ORANGE for an aggressive
setting.
• DIM RED for a more aggressive setting.
6. Release brake pedal.
2. Set Power Knob to the 12 o’clock position.
slide knob.
power.
stops to check the Power and Level adjustments. The automatic response (brake pedal)
is initiated and terminated via the stoplight
switch. When the brake pedal is released,
trailer braking will cease.
Fine Tuning
tune the level setting for the majority of the stopping that you will be doing.
❑ You have an Aggressive Setting: To
correct this condition rotate level knob
to the LEFT (clockwise - more
Delayed).
❑ You have a Delayed Setting: To correct
this condition rotate level knob to the
RIGHT (counter-clockwise – more
Aggressive)
2. Repeat until desired trailer braking is
achieved.
NOTE:
4. Not all trailer brakes will lock up due to various conditions.
brake control.
Envoy Troubleshooting Chart
B. Light is Dim RED or flashing RED.
C. Light glows dim RED and gets brighter as POWER
Knob is decreased.
Braking with foot pedal is too aggressive
Braking is delayed for extended period.
Tow vehicle connected to trailer, brake pedal depressed:
A. No RED light.
1.
2.
1.
2.
3.
4.
1.
2.
1.
2.
1.
2.
1.
2.
1.
2.
3.
4.
5.
Probable Cause
Corrosion on trailer plug contact.
Loose POWER or GROUND connection.
POWER set at or near minimum.
Short on BRAKE line (BLUE wire).
BLACK & WHITE wires reversed, control destroyed.
12 volts from external source on BRAKE line (BLUE wire)
Open on GROUND line (WHITE wire).
Defective brake magnets.
Sensor set too aggressive, see LEVELING SENSOR.
Power set too high.
Sensor set improperly, see LEVELING SENSOR.
Power set too low.
Vehicle not moving, need to be moving for brakes to apply.
No signal from brake light, test voltage on RED wire.
Bad connection to RED wire.
Technical
Situation
Tow vehicle connected to trailer,
NO GREEN light.
Tow vehicle connected to trailer, light is GREEN.
When Manual Slide Knob is activated:
A. No RED light.
P/N 5288 Rev G
B-10
®
VOYAGER INSTRUCTIONS
Instructions for Voyager Brake Control
70°
For 2, 4, 6* and 8* brake applications
(*6 and 8 brake for XP model only]
READ THIS FIRST:
6. Release brake pedal.
future reference.
0°
D
-20°
E
A
A
B
B
C
A.
B.
C.
D.
E.
Power Knob
Manual Slide Knob
Bi-Colored Light
Level Knob
Technical
B-11
2. Reversing the connection to a breakaway battery on the trailer will destroy the brake
control.
4. The light is:
•GREEN when trailer is connected
•RED when brake pedal or manual is
activated and trailer is connected.
5. The GREEN light draws 10 milliamperes of
current from tow vehicle. It would take over
5,000 hours to drain the tow vehicle battery.
actuated.
www.tekonsha.com
Installation Guide
NOTE: The Brake Control must be mounted
from -20 degrees nose down to 70 degrees nose
up. (See Below). Failure to install brake control within these constraints may cause your
control to become inoperable.
NOTE: Range of adjustment for the level
knob from DIM ORANGE to DIM RED is 20
degrees of rotation.
NOTE: When the brake control is leveled
Trailer Brakes
A.
B.
Mounting Bracket
#6 x 3/8” Screws
NOTE:
damage unit.
screws until snug.
Leveling the Sensor
NOTE:
1. .This brake control is activated by inertia
and requires the level to be set properly, or
the braking response will be too harsh or
ineffective.
2. To properly level the sensor, the trailer and
tow vehicle must be parked on a level surface and trailer must be connected to tow
vehicle.
1. Connect trailer to tow vehicle, Bi-Colored Light
should glow GREEN.
2. Set power knob to maximum by fully rotating
clockwise.
3. Depress tow vehicles brake pedal and hold.
4. Rotate the Level Knob counter-clockwise
(towards the back of the control) until the BiColored Light starts to change colors from
GREEN to RED.
5. Carefully rotate the Level Knob clockwise
(towards the front of the control) until a
shade of ORANGE is visible.
Bi-Colored Light should show:
•DIM ORANGE for a typical setting.
•BRIGHT ORANGE for an aggressive setting.
•DIM RED for a more aggressive setting.
2. Set Power Knob to the 12 o’clock position.
slide knob.
(Rotate power knob toward the 8 o’clock position, counter-clockwise)
❑ Turn power up using power knob. (Rotate
power knob toward the 5 o’clock position,
clockwise)
power.
stops to check the Power and Level adjustments. The automatic response (brake pedal)
is initiated and terminated via the stoplight
switch. When the brake pedal is released,
trailer braking will cease.
Fine Tuning
tune the level setting for the majority of the stopping that you will be doing.
❑ You have an Aggressive Setting:
knob clockwise, toward you, see
below.
❑ You have a Delayed Setting:
knob counter-clockwise, away from
you, see below.
2. Repeat until desired trailer braking is
achieved.
®
VOYAGER INSTRUCTIONS
NOTE:
B
A
C
A. Delayed
B. Normal
C. Aggressive
4. Not all trailer brakes will lock up due to var-
ious conditions.
brake control.
Voyager Troubleshooting Chart
B. Light is Dim RED or flashing RED.
C.Light glows dim RED and gets brighter as POWER
Knob is decreased.
Braking with foot pedal is too aggressive
Braking is delayed for extended period.
Tow vehicle connected to trailer, brake pedal depressed:
A. No RED light.
1.
2.
Probable Cause
Loose POWER or GROUND connection.
1.
2.
3.
4.
1.
2.
1.
2.
1.
2.
1.
2.
1.
2.
3.
4.
5.
POWER set at or near minimum.
12 volts from external source on BRAKE line (BLUE wire).
Defective brake magnets.
Sensor set too aggressive, see LEVELING SENSOR.
Power set too high.
Power set too low.
Vehicle not moving, need to be moving for brakes to apply.
No signal from brake light, test voltage on RED wire.
Bad connection on RED wire.
Technical
Situation
Tow vehicle connected to trailer,
NO GREEN light.
Tow vehicle connected to trailer, light is GREEN.
When Manual Slide Knob is activated:
A. No RED light.
P/N 3840 Rev I
B-12
®
PILOT INSTRUCTIONS
Instructions for Pilot Brake Control
For 2 to 6 brake applications
READ THIS FIRST:
future reference.
• Manual Slide or Tow Vehicle Brakes applied
and trailer Connected, typical ones and tenths
voltage display.
(Shown “Right Side Up”)
E
B
• Manual Slide or Tow Vehicle Brakes applied
and trailer Connected, typical tens and ones
voltage display.
NOTE:
Display shows tenths of a volt up to
9.9. After 9.9 the display shows whole digits only.
Installation Guide
C
A
A
A.
B.
C.
D.
E.
4. Using mounting ball as a template drill (3)
1/16” holes for a #6 screw size.
5. Permanently secure mounting ball using
(3) #6 x 3/8” screws supplied.
6. Insert mounting screw through bottom of the
control.
7. Place foam gasket on top of the control
inserting mounting screw through hole in
gasket.
8. Attach control to mounting ball.
9. Rotate control to desired position and tighten
mounting screw until snug.
Right Side Up
Right Side Up
Check behind dash for wires, etc.
before drilling.
Upside Down
B
Power Knob
Manual Slide Knob
Anchor and Pivot Holes
Two Digit Power Display
Optional Ball Mount Interface
2 Digit Power Display Legend
NOTE:
Changing the Display Orientation
D
2. Reversing the connection to a breakaway
battery on the trailer will destroy the brake
control.
Information call 1-888-785-5832 or
www.tekonsha.com
1. Using mounting ball, find a desired location.
2. Attach double sided tape to back of mounting
ball.
3. With the other side of the double-sided tape,
temporarily attach mounting ball to desired
location.
C
A. Mounting Bracket
C. Mounting Holes
NOTE:
damage unit.
screws until snug.
Upside Down
To change the display orientation from right
side up to upside down:
1. Connect white, red and blue wire to tow vehicle.
2. While applying the brake pedal or manual
slide knob, connect Black Wire (Battery) to
the tow vehicle.
3. Display should now be upside down.
NOTE:
If using a wiring harness, apply brake
pedal or manual slide knob while snapping
connector to tow vehicle.
Optional Mounting Ball
(Purchased Separately)
A
B
Technical
D
• Unit has power and is Connected to a trailer
load.
B-13
C
• Manual Slide or Tow Vehicle Brakes applied,
unit is wired properly and trailer NOT
Connected.
A.
B.
C.
C.
Double Sided Tape
Mounting Ball
Foam Gasket
Mounting Screw
Right Side Up
Upside Down
To change the display orientation from upside
down to right side up:
1. Disconnect Black Wire (Battery) from tow
vehicle.
2. Wait 5 seconds.
3. Reconnect Black Wire (Battery) DO NOT
apply brake pedal or manual slide knob while
connecting wire.
®
PILOT INSTRUCTIONS
Trailer Brakes
Once the control has been installed, it is necessary to set the power needed to stop the trailer
during a braking event.
2. Locate the manual slide knob and power
knob on the control.
3. While applying the manual slide knob turn
power knob until display reads 4.0.
slide knob.
power.
NOTE:
2. Braking performance may be sluggish in
sub-freezing temperatures. Allow adequate
time for the controller to warm prior to use
in sub-freezing temperatures.
directional stability of trailer and tow vehicle. The power may need to be adjusted for
different load weights and road conditions.
Pilot Troubleshooting Chart
Tow Vehicle connected to trailer,
Manual Slide Knob or Brake Pedal is activated:
A. Only “.” on two digit display.
B. 0.0 or less than 1.0 on two digit display.
C.5.0 - 6.0 on two digit display. (Power set to MAX)
Braking with foot pedal is too aggressive.
Braking with foot pedal is too light.
1.
Probable Cause
Poor connection on POWER (BLACK wire) or GROUND (WHITE wire).
1.
2.
3.
4.
Poor connection on POWER (BLACK wire) or GROUND (WHITE wire).
Poor connection on BRAKE line (BLUE wire).
12 volts from external source on BRAKE line (BLUE wire).
1.
1.
2.
3.
1.
1.
1.
Power set too low.
Power set too high.
Power set too low.
Technical
Situation
No Trailer connected,
Manual Slide Knob or Brake Pedal is activated:
No “.” on two digit display.
Tow Vehicle connected to trailer,
Manual Slide Knob or Brake Pedal NOT ACTIVATED:
No “.C” on two digit display.
P/N 7842 Rev D
B-14
®
ACCUTRAC INSTRUCTIONS
Instructions for AccuTrac Brake Control
Tune the sensor, the arm can be moved to change
the switching level. This needs to be done after
the soft and hard effort levels are set.
Installation Guide
For 2, 4 and 6* brake applications.
(*6 brake for SX model only.)
A
NOTE:
READ THIS FIRST:
future reference.
B
A
C
B
C
D
A. Mounting Bracket
C. Mounting Holes
NOTE:
damage unit.
E
F
A.
B.
C.
D.
E.
F.
Hard Effort Brake Setting
Soft Effort Brake Setting
Bi-Color Light
Manual Slide Knob
Internal Sensor Adjustment Arm
Technical
4. The light is:
• RED when brake pedal or manual is
• Flashing RED or OFF when trailer is
not connected.
5,000 hours to drain the tow vehicles battery.
6. The Internal Sensor Adjustment is CRITICAL.
This adjustment determines the transition
point from low effort braking to hard effort
braking.
www.tekonsha.com
screws until snug.
4. Once the brake control is securely mounted,
point the Internal Sensor Adjustment Arm
down to the ground. (See Below)
NOTE:
The Brake Control must be mounted
from 20 degrees nose down to 70 degrees nose
up. (See Below)
70°
2. Set HARD adjustment slide to mid-position.
3. Tow trailer at low speed (20-30 mph) on a
level, dry and paved surface and apply Manual
Slide Knob.
✓ If trailer brakes DO NOT lock up:
❑ Increase HARD braking effort by
sliding HARD adjustment to the right.
✓If brakes DO lock up:
❑ Decrease HARD braking effort by
sliding HARD adjustment to the left.
4. Repeat step (3) until HARD braking effort has
been set to a point just below wheel lock up
or at a sufficient force as to achieve maximum
braking power.
Setting the “Soft” Effort
Adjustment
0°
-20°
Setting Up the Brake Control
The brake control has independent soft and hard
effort brake settings.
• Soft Effort – setting for gradual stops,
which allows for effective braking without
the wheel “hop”
• Hard Effort – setting for hard or panic
stop, which is sensed by the Internal
Sensor and braking effort is automatically
switched over to the Hard Effort Setting.
Setting the Internal Sensor Arm
Once the brake control is securely mounted, the
internal sensor adjustment arm must be pointed
directly toward the floor of the vehicle. To Fine
B-15
Setting the “Hard” Effort
Adjustment
1. After the HARD effort has been set, adjust the
SOFT effort adjustment to mid-position.
2. Make a soft stop, such as stopping at a stop
sign, etc.
✓ If braking is too aggressive:
❑ Decrease SOFT braking effort by
sliding SOFT adjustment to the left.
✓ If braking is too light:
❑ Increase SOFT braking effort by sliding
SOFT adjustment to the right.
3. Repeat step (2) until SOFT braking effort is
noticeable but not aggressive.
NOTE:
1. If during your attempts to set the SOFT
effort control, the braking was too aggressive
even with the SOFT effort set to a minimum, the INTERNAL SENSOR ARM is not
set correctly, review Setting the Internal
Sensor Arm.
2. The HARD effort adjustment must be set to
allow for proper activation of brakes at
quick (hard/fast) stops.
3. Adjustment of SOFT and HARD efforts may
be necessary to compensate for changing
road conditions, trailer loading, and conditions of trailer brakes.
®
ACCUTRAC INSTRUCTIONS
Fine Tuning the Brake Control
To fine tune the sensor, the arm can be moved to
change the switching level.
NOTE:
vehicle. This will cause the switching level to
be a higher braking effort (HARD effort braking will be controlled by tow vehicle, and the
trailer braking will be less than maximum.)
Only small movements of the internal
sensor adjustment arm are needed to cause
noticeable differences in the braking response.
• AGGRESSIVE – move pointer toward rear of
vehicle. This will cause the switching level to
be a lower braking effort. (Gradual stops now
become more aggressive.)
• NORMAL - recommended starting point
before fine tuning, if necessary.
• DELAYED – move pointer toward front of
AccuTrac Troubleshooting Chart
Trailer braking is weak.
Light is GREEN / RED.
Trailer braking is weak or inconsistent
Light is OFF, Flashing RED or DIM.
Trailer braking is too strong.
Trailer brakes locked when connected to vehicle.
Light is RED.
Light is GREEN all the time
Probable Cause
- HARD Effort set to minimum, adjust to a higher setting.
-
SOFT Effort set to minimum, adjust to a higher setting.
Adjustment Arm not set correctly.
RED (stoplight) wire connected incorrectly.
SOFT Effort set too low, adjust to a higher setting.
Brake control grounded to interior of vehicle.
Trailer is not connected to vehicle.
Open circuit on brake line.
Ground connection is poor.
No POWER to unit through BLACK wire.
SOFT Effort set too high, adjust to a lower setting.
Adjustment Arm not set correctly.
Breakaway system employed.
Short from brake line to ground.
Technical
Situation
No trailer brakes with manual knob activated.
Light is GREEN.
No trailer brakes with foot pedal depressed.
Light is GREEN.
P/N 7301 Rev S
B-16
®
POD INSTRUCTIONS
Instructions for Pod Brake Control
For 2 to 4 brake applications.
READ THIS FIRST:
future reference.
A
• RED when brake pedal or manual is
• Flashing RED or OFF when trailer is
not connected.
5,000 hours to drain the tow vehicles battery.
Information call toll-free-: 1-888-785-5832 or
www.tekonsha.com
Installation Guide
D
C
A
B
B
NOTE:
C
A.
B.
C.
D.
Power Knob
Manual Slide Knob
Bi-Colored Light
4. The light is:
sary to set the power needed to stop the trailer
during a braking event.
2. Locate the manual slide knob and power
knob on the control.
3. Turn power knob to minimum. Turn power
knob in the + direction about a 1/4 of a turn.
slide knob.
power.
A. Mounting Bracket
C. Mounting Holes
NOTE:
damage unit.
screws until snug.
Trailer Brakes
Once the control has been installed, it is neces-
3. The driver may find it necessary to readjust
the power to a lower setting for extended
periods of in town stop and go driving. It is
always good practice to readjust the power
when returning to highway driving
Pod Troubleshooting Chart
Situation
No trailer brakes with manual knob activated.
Light is GREEN.
No trailer brakes with foot pedal depressed.
Light is GREEN.
Trailer braking is weak.
Trailer braking is weak or inconsistent
Light is OFF, Flashing RED or DIM.
Technical
Trailer braking is too strong.
Trailer brakes locked when connected to vehicle.
Light is RED.
Light is GREEN all
the time
Probable Cause
- POWER set to minimum, adjust to a higher setting.
-
POWER set to minimum, adjust to a higher setting.
POWER set too low, adjust to a higher setting.
Brake control grounded to interior of vehicle.
Trailer is not connected to vehicle.
Open circuit on brake line.
Ground connection is poor.
No POWER to unit through BLACK wire.
POWER set too high, adjust to a lower setting.
-
Breakaway system employed.
Short from brake line to ground.
P/N 7760 Rev F
B-17
BRAKE CONTROL WIRING HARNESS CHART
Brake Control Wiring Harness Chart
WARNING When using a wiring harness supplied by your vehicle’s Manufacturer (OE Harness), DO NOT MATCH COLORS. Please follow wiring chart below.
OE HARNESS
Chevrolet
Red
Light Blue
Black
Dark Blue
Brown
BRAKE CONTOL WIRE
Black
Red
White
Blue
N/A
+12 Volts
Stoplight
Ground
Trailer Brakes
Black
Red
White
Blue
+12 Volts
Stoplight
Ground
Trailer Brakes
Black
Red
White
Blue
+12 Volts
Stoplight
Ground
Trailer Brakes
Black
Red
White
Blue
N/A
+12 Volts
Stoplight
Ground
Trailer Brakes
Black
Red
White
Blue
N/A
+12 Volts
Stoplight
Ground
Trailer Brakes
New Dodge (Green Wire)
White w/ Red Tracer
Blue w/ White Tracer
Green w/ Black Tracer
Blue
Dodge
Red w/ Black Tracer
White w/ Tan Tracer
Black
Blue
New Ford (Pink Wire)
Pink
Red
White
Blue
Brown
Red
Lt Green
White
Dark Blue
Brown
Technical
Ford
P/N 7854 Rev A
B-18
TRAILER EMULATOR REFERENCE
Trailer Emulator Reference Guide
9055 – Sentinel
Trailer Emulator
Brake Control’s light should be:
• GREEN – with trailer emulator connected with
no manual slide activation.
• GREEN to varying colors of RED – trailer
emulator connected and manual slide activated.
9010 - Commander
9020 - Commander XP
LT – Left turn signal, Red Light
TL – Tail / running lights, Red Light.
RT – Right turn signal, Red Light.
12V – 12 volt battery supply line, Red Light.
BK - Electric trailer brakes, Red Light.
BU – Backup lights, Red Light.
Brake Control’s lights should be:
• Level LED is GREEN – with trailer emulator
connected with no manual slide activation.
• Level light changes color from GREEN to
RED and the other FOUR RED lights
should light in progression – trailer emulator connected and manual slide activated.
User’s Guide
9040 - Envoy
9045 - Envoy SX
The Trailer Emulator requires the ground and 12
volt battery line to be properly connected in order
to check the electric brake circuit.
• 12 volt light on the emulator will be lit as
soon as the emulator is connected to the tow
vehicle’s plug. If this does not happen see
Troubleshooting Chart.
• The RT, LT, TL and BU lights will light on the
emulator as those functions are activated on
the tow vehicle. If this does not happen see
Troubleshooting Chart.
• The BK light on the emulator should be off
until the brake control is activated. NOTE:
The trailer emulator is not an exact trailer
load so the light displays on various brake
controls will respond differently.
Brake Control’s lights should be:
• 1st light should be GREEN – with trailer
emulator connected with no manual touch
pad activation.
• Varying Colors of RED – trailer emulator
connected manual touch pad activated.
2030 - MARK 12
• GREEN – with trailer emulator connected with
• GREEN to varying colors of RED – trailer
emulator connected and manual slide activated.
9030 – Voyager
9035 – Voyager XP
• OFF – with trailer emulator connected with
• Varying Colors of RED – trailer emulator
connected and manual slide activated.
The following can be expected with
Tekonsha Brake Controls:
Trailer Emulator Troubleshooting Chart
Condition
Trailer Emulator connected to tow vehicle
- 12 V LED is NOT lit on Trailer Emulator
-
-
Probable Cause
LT LED is NOT lit on Trailer Emulator
NOTE: Applies for LT, RT, TL and BU LEDs
BK is NOT lit on Trailer Emulator when manual slide / touch pad is
activated, but 12 V LED is lit.
BK is NOT lit on Trailer Emulator when Brake Pedal is depressed, but
12 V LED is lit.
Technical
NOTE:
The following two methods are available to test
the Automatic response of the Tekonsha brake
control with the Trailer Emulator.
1. Vehicle in Motion Method
• Connect Trailer Emulator to vehicle
• Properly adjust the Level of the brake control.
• Drive vehicle and apply brake pedal, the
1.
2.
1.
2.
1.
2.
3.
Bad ground or incorrect wiring in tow vehicle connector.
No 12 volt battery power supplied to connector.
Bad ground or incorrect wiring in two vehicle connector.
Loose or poor connection in circuit under test.
Bad ground or incorrect wiring in tow vehicle connector
Poor ground on Brake Control. Brake Control goes into a limit mode.
Gain adjustment on Brake Control is set to minimum, adjust gain to
maximum and retest using manual.
1. If using brake pedal, Tekonsha's inertia activated controls require vehicle movement to activate sensor. Apply the manual switch and see if BK
LED lights. (SEE NOTE)
brake control’s light should indicate a
braking event.
2. Aggressive Level Method
• Connect Trailer Emulator to vehicle
• Properly adjust the Level of the brake control.
• Adjust Level setting toward Aggressive.
• The brake control’s light should indicate
a braking event.
• When finished with test remember to
adjust the brake control’s level back to
desired tow setting.
Tekonsha Technical Support
1-888-785-5832
www.tekonsha.com
(Outside the USA & Canada )
517-767-4142
P/N 6558 Rev D
B-19
AMP METER INSTRUCTIONS
Instructions for Amp Meter
Installation Guide
1. Locate meter in such a way as to be accessible to
the blue wire coming from the brake control in
your vehicle. The installation of the Tekonsha Amp
Meter should not require cutting of wires or disconnection of the control in most installation
applications.
2. Locate wire clip in package and install on back of
amp meter.
3. Simply slip the unit over the blue wire in such a
way as the brake control is on the right side of the
amp meter with the wire passing from the right to
left.
4. Stroke the manual lever on your control with your
trailer connected and you should see the current
displayed on the analog gauge. If the needle does
not move, the wire is threaded in the wrong direction. Wire must pass from the control on your
right to the left. See illustration, snap wire clip in
place securely.
5. Your amp meter is shipped with the scotchmate
fastening system. Select the flattest area of your
dash to mount the gauge. Be sure surface is clean
and dry. With mated scotchmate strips pressed
together, peel off backing from one side and apply
adhesive side of strips to mounting bracket back
and snap amp meter into housing. Remove backing from other side of strips and place in the
decided location.
6.
WARNING This fastening system is intended
for permanent bonding. Surface damage may
occur if removal of mounting is necessary. To
properly and permanently adhere, tape must be
applied when surfaces are above freezing (32°F).
NSHA
TEKEOCONTROL
BRAK
BLUE
WIRE
FROM
CONTROL
TO TRAILER
BRAKES
FRONT
BACK
BLUE WIRE
TO BRAKES
Technical
BLUE WIRE
FROM CONTROL
P/N 5725 Rev. 0396
B-20
POSITIVE GROUND CONVERSION KIT INSTRUCTIONS
Instructions for Positive Ground Conversion Kit
Installation Guide
1. Install the Brake Control per the directions in
the installation manual.
A. Black Wire to (+) Positive Battery
Terminal.
B. White Wire to (-) Negative Battery
Terminal.
C. Blue Wire to Trailer’s Brake Magnets.
D.Red Wire to Red Wire on the 3191 Positive
Ground Conversion Kit.
2. Install the 3191 Positive Ground Conversion
Kit per the Wiring Diagram shown.
A. Black Wire to (+) Positive Battery
Terminal.
B. Red Wire to Red Wire on the Brake
Control.
C. Green Wire to the COLD SIDE of the STOPLIGHT SWITCH. (The side that goes directly
to the stop light lamps, not the side that
goes to the battery.)
3. IMPORTANT ! THE TRAILER MUST BE
REWIRED. The normal connection of the
return line from the brake magnets that is
grounded to the trailer’s chassis MUST be
rewired.
NOTE:
THE BRAKE MAGNET RETURN LINE
MUST BE REWIRED TO THE (-) NEGATIVE
BATTERY TERMINAL IN THE TOW VEHICLE. THE BRAKE-AWAY SWITCH AND BATTERY MUST ALSO BE REWIRED PER THE
WIRING DIAGRAM.
Technical
P/N 3080 REV B
B-21
PULSE PREVENTER INSTRUCTIONS
Instructions for Pulse Preventer
Prevents brakes from pulsing when 4-way
flashers are in use.
1. Diode & L-Bracket will get warm with long
brake times, keep clear and do not cover with
tape or other materials.
2. Make certain when splicing into the wire from
the cold side of the stoplight switch, the position of the switch is not disturbed.
Installation Guide
1. Mount Pulse Preventer in close proximity to
brake light switch.
2. Cut brake wire from cold side of stoplight
switch, making sure to leave it long enough to
splice it.
3. Connect YELLOW wire from pulse preventer
and RED wire from brake control to wire coming out of cold side of stoplight switch.
4. Connect remaining wire (from step 2 that was
cut) coming from brake lights to BROWN wire
of pulse preventer.
www.tekonsha.com
Side
Cut existing wire & insert diode
Yellow
12 V
Battery
Vehicle
Stoplight
Switch
NOTE:
FORD 1989-1991:Per Ford instructions: electric
brake controls must splice into the stoplight line
via the turn signal connector harness and not
directly to the stoplight switch. The turn signal
harness is located near the steering column. The
harness has a crescent shaped connector which
has 4 positions in the inner row and 7 positions
in the outer row. The wire which is the cold side
of the stoplight switch should be located in the
second position in the outer row of 7. The color
of the wire is light green for all F100-350s.
To Stoplights
Brown
Pulse Preventer
Brake
Control
Technical
Application:
P/N 2179 REV D
B-22
BREAKAWAY SYSTEMS APPLICATIONS/WIRING
BREAKAWAY SYSTEMS
APPLICATIONS / SPECIFICATIONS GUIDE
APPLICATIONS
BREAKAWAY SYSTEM MODEL #
1026
2026
20005
20010
1028
2028
20015
20020
Single Axle
X
X
X
X
X
X
X
X
Tandem Axle
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1028
2028
20015
20020
X
X
For Electric Trailer Brake Systems
Tri-Axle*
*Requires a minimum 5 Amp/Hr Battery
Four Axles*
*Requires a minimum 5 Amp/Hr Battery
SPECIFICATIONS
BREAKAWAY SYSTEM MODEL #
A-Frame or Post Mount System
1026
2026
X
X
20005
20010
U-Shaped Clamp Style Fastener Mounts Over Most Trailer Tongues
Flat Surface Mount System (Screws or Bolts)
X
X
For Use With Self Tapping Screws Or Similar Fasteners
Weldable Flat Surface Mount System
X
X
Weldable Metal Mounting Bracket Or for use w/Self Tapping Screws
Lockable Box Feature
Heavy Duty Nylon Breakaway Switch
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Reinforced Nylon Case With Weldable Tab & 48” Coated Lanyard
DC to DC Accelerated Battery Charging Device (ABCD)
X
Minimal Charging Capacity for Partially Depleted Batteries...
Not Effective for Batteries Under 7 Volts Remaining Charge
Full Capacity and Temperature Compensated DC to DC
4 Amp/Hr Heavy Duty Quick/Maintenance (Two Stage) Charger
Maximum Charging Capacity Even If Battery Is Almost Fully Depleted ...
Effective With Batteries Down To 1 Volt Remaining Charge
4 Amp/Hour Sealed Lead Acid Battery
5 Amp/Hour Sealed Lead Acid Battery
X
X
X
X
X
Batteries Require Periodic Recharging To Maintain Optimum Performance
SCHEMATIC WIRING DIAGRAM FOR BREAKAWAY SWITCH
Fasten cable to tow vehicle securely. Be certain
that cable has no restrictions, and will not be
restricted in case of trailer breakaway.
DO NOT HOOK TO CHAIN
LOOP OR HITCH BALL.
Mount switch with 1/4” bolt thru trailer frame. Secure with lock nut or
2 jam nuts (not included). DO NOT OVER TIGHTEN. PROPERLY INSTALLED
_
SWITCH MUST BE ABLE TO PIVOT.
+
TOW VEHICLE
Always mount Breakaway Switch
with pull cable towards tow vehicle.
“HOT” line from
Brake Control
Technical
B-23
ATTENTION INSTALLER: Please
give this sheet to consumer
upon completion of installation.
Battery
12 Volt
Electrical Connector
Tow Vehicle Ground
SAFETY ITEM: Solder all wire connections.
1. Mount Battery case securely to frame, jack post or other suitable location on trailer.
2. Bolt breakaway switch bracket to frame of trailer or battery case bracket using
1/4” bolt and lock nut or (2) 1/4” jam nuts. (Bolt and nuts not included in kit.)
CAUTION: Do not over tighten bolt. Switch must be able to pivot.
3. Check and install battery.
4. Wire per schematic diagram. Properly insulate all connections.
5. Attaching to tow vehicle: Attach cable to tow vehicle frame being certain no strain is
placed on cable. CAUTION: Do not hook cable to safety chain loop or hitch ball.
Splice to
Brake “HOT” line
“HOT”
line to
Trailer
Brakes
Ground
CAUTION:
1. Switch location should be selected to ensure unobstructed line of
pull in event of vehicle separation.
2. Do not let cable drag on ground.
3. Check condition of batter prior to each trip.
5. WARNING: Disconnect trailer plug before testing
breakaway unit. Failure to do so will result in severe
damage to electronic brake control.
For service call Tekonsha Engineering (517) 767-4142
SHUR SET III ® INSTALLATION
Shur Set III® Instructions and Installation
HEAVY DUTY QUICK/MAINTENANCE TWO STAGE CHARGER
+12 Volt System
Stop Light Switch
+12 V BLACK (+)
RED
BLACK
+
+12 Volt
Battery
–
Automatic
Reset
Circuit
Breaker
-
RED (+)
TOW
CHARGER
+
RED
WHITE (–)
Breakaway
Switch
BLUE
Brake
Control
TRAILER
BRAKES
TOW VEHICLE
CHASSIS GROUND
ABCD (Accelerated Battery Charging Device)
+12 Volt System
Stop Light Switch
+12 Volt
Breakaway
Battery +12 V
RED
ABCD
BLACK
To maximize the life of the battery the
following conditions should be met:
+
+12 Volt
Battery
–
Automatic
Reset
Circuit
Breaker
BLACK (+)
+
RED
BLUE BLUE
BLUE
Breakaway
Switch
Brake
Control
TRAILER
BRAKES
Technical
12 Volt Sealed Lead-Acid
Battery
1. Avoid over or undercharge. This is the single
worst enemy of lead-acid batteries.
2. Batteries should not be stored in a discharged state or at elevated ambient temperatures.
3. Avoid exposing batteries to heat! Service life
is shortened considerably at ambient above
30°C (86°F).
4. Due to the characteristics of this battery, after
six to nine months of storage, the battery
should be recharged.
5. Charge the battery at the proper rate.
Current should be limited to 1.2 amps or
less. Charge current above 2.3 amps will
result in shortened service life.
+12 Volt
Breakaway
Battery
TRAILER
1. Improper installation of the breakaway battery will destroy the brake control. The negative terminal must attach to ground and positive terminal must attach to the breakaway
switch.
2. Check your breakaway system periodically to
insure that wiring and connections are
secure. A short or an open circuit can result
in a no-brake condition.
3. If excessive discharging of the breakaway battery occurs, check battery and recharge using
a Heavy Duty Two Stage/Maintenance Charger.
If using a commercial (AC to DC) make certain the 12 volt charge is limited to 1.2 amps
or less.
4.. If the secondary battery needs charging, current will be drawn from the tow vehicle’s battery at anytime the tow vehicle is connected
to the trailer. The most current which will be
drawn is 1.2 amps.
5. To only charge the breakaway battery when
vehicle is running, a battery isolator may be
installed in the 12 volt supply line (BLACK
wire for tow charger).
TOW VEHICLE
•12 VOLT
•P/N 1023 – 4 amp/hr – max discharge current
20 hr. rate = 225 mA
•P/N 2023 – 5 amp/hr – max discharge current
20 hr. rate = 250 mA
•Maximum Discharge Current = 40 amps
•Maximum charge current must be limited to
1.2 amps
•P/N 1023, P/N 2023: Length = 3.54”
Width = 2.76” Height = 4.13”
Weight = 3.8 lbs
Terminals: Fasten Tab .187” x .032”
•Service Life: Under normal operating conditions, 4-5 years in standby applications or 2001000 charge/discharge cycles depending upon
depth of discharge and rate of charge.
TRAILER
1. Remove Charger and Battery from the battery
case.
2. Mount battery case securely to frame, jack
post or other suitable location on trailer.
3. Bolt breakaway switch to frame of trailer or
battery case bracket.
4. Check and install battery and charger into
the battery case. Feed wires out the back,
then close the top.
www.tekonsha.com
Battery Data Chart
TOW VEHICLE
Installation Guide
6. Provide adequate air circulation when charging battery. Do not charge battery in any
other container besides the supplied battery
box.
7. Do not place batteries in close proximity
to objects which can produce sparks or
flames.
8. Do not expose battery case to organic solvents or adhesives.
9. Do not attempt to disassemble batteries.
Contact with sulfuric acid may cause
harm.
10. Fasten batteries tightly and make provisions for shock absorption if exposure to
shock or vibration is likely.
11. Do not throw batteries into fire; batteries so
disposed may rupture or explode.
WHITE
Check condition of battery prior to installation and
prior to each trip.
WHITE
READ THIS FIRST:
TOW VEHICLE
CHASSIS GROUND
P/N 2218 REV N
B-24
CONNECTOR WIRING DIAGRAMS
7-WAY CONNECTOR WIRING DIAGRAM
7-WAY MOLDED TRAILER/
SEALED CAR CONNECTOR & CABLE
7-WAY THERMO-PLASTIC/
METAL CONNECTOR
BLACK
GREEN
BLACK
RED
BROWN
WHITE
BLUE
GREEN
BLACK
GREEN
BROWN
BROWN
RED
RED
BLUE
BLUE
WHITE
TRAILER END
As viewed from front
face of 7-way connector
with molded on cable.
YELLOW
CAR END
with sealed cable.
7 - W AY
WHITE
YELLOW
TRAILER END
As viewed from core
back side where wires are
attached with screws.
W I R I N G
CAR END
As viewed from core
back side where wires are
I N D E X
Wire Color & Gauge
Molded Trailer/Sealed
Car Connector Terminal
Thermo-Plastic/Metal
Connector Terminal
White / 10 gauge
Blue / 12 gauge
Green / 14 gauge
Black / 10 gauge
Red / 14 gauge
Brown / 14 gauge
Yellow / 14 gauge
Common Ground
Electric Brake
Tail & License
Battery Charge
Left Stop & Turn
Right Stop & Turn
Center Auxiliary
#1
#2
#3
#4
#5
#6
#7
Common Ground
Electric Brake
Tail & License
Battery Charge
Left Stop & Turn
Right Stop & Turn
Center Auxiliary
6-WAY MOLDED TRAILER/
SEALED CAR CONNECTOR & CABLE
6-WAY ZINC DIE-CAST
CONNECTOR
GREEN
BROWN
BLUE
WHITE
WHITE
BLUE
WHITE
BLUE
RED
GREEN
YELLOW BROWN
YELLOW
RED
TRAILER END
with molded on cable.
CAR END
with sealed cable.
6 - W AY
BROWN
TRAILER END
CAR END
As viewed from core
As viewed from core
back side where wires are back side where wires are
W I R I N G
I N D E X
Wire Color & Gauge
Molded Trailer/Sealed
Car Connector Terminal
Zinc Die-Cast
Connector Terminal
White / 10/14 gauge
Blue / 10/14 gauge
Green / 14 gauge
Red / 10/14 gauge
Brown / 14 gauge
Yellow / 14 gauge
Common Ground
Electric Brake
Right Stop & Turn
Auxiliary
Tail & License
Left Stop & Turn
GD - Common Ground
S - Electric Brake
TM - Tail & License
LT - Left Stop & Turn
RT - Right Stop & Turn
A - Auxiliary
Technical
4-WAY METAL CONNECTOR
AUXILIARY
TAIL MARKER
STOP
GROUND
4-WAY FLAT CONNECTOR
WHITE
(Ground)
AUXILIARY
BROWN
(Tail, License, Sidemarker,
Clearance & I.D. Lamps)
YELLOW
(Left Turn & Stop)
TAIL MARKER
TRAILER END
CAR END
As viewed from core
As viewed from core
back side where wires are back side where wires are
B-25
YELLOW
GREEN
(Right Turn & Stop)
TRAILER END
CAR END
ELECTRIC TRAILER BRAKE PART IDENTIFICATION
Manufacturer Identification
AL-KO
AL-KO levers are very flat. The brake shoes do not have anything unusual about them. AL-KO uses only one return spring at the top on both
10 and 12-inch units. With the drum off, you can tell what size the system is if the magnets have never been replaced. The 10-inch brake will
have a magnet with light green wires and the 12-inch brake will have white wires.
Dexter
Dexter uses a stamp on the back of the backing plate that identifies the size of the brake. Looking on the back side you will see a triangle.
Around the triangle you will see Dexter and the size (i.e. 10" X 2 1/2" or 12" X 2"). Dexter uses 2 return springs on all late model brakes; some
early 12-inch brakes used a single return spring.
Hayes
Hayes brake shoe webs have a tooth that hangs down at the top and use a single return spring. Early 12-inch brakes used a dual return spring.
Hayes axle is owned by AL-KO. AL-KO backing plates have been seen on some of the new Hayes axles. It looks as if they are still using the Hayes
name and are starting to use AL-KO parts.
Fayette
Fayette axles are obsolete. If you find a Fayette axle tag and the trailer is worth keeping you should consider changing the axles to AL-KO or
Dexter. At that time it is recommended that the spring hangers and bushings also be replaced.
Brake Size Identification
Axle Identification
Axles generally have an ID tag located on the axle crossbar that gives you the axle capacity. Check there first. This would
give you a starting reference point.
Brake Drum / Shoe Size
Measuring is the same for all brands. Using a tape measure you can do a random measurement as to the diameter by
measuring across the drum. If it is a 10-inch drum you will measure approximately 11 inches across for an outside measurement. The 12-inch brake will measure approximately 13 inches for an outside measurement. The drum would need
to be removed to get the correct diameter and width.
Magnet Identification
Dexter 7" X 1 1/4"
The magnets are round. Prior to April 1990 they had yellow wires, after 1990 the magnet has white wires. Replacement of
magnets will need to be done in pairs and updated to the new magnet along with the lever. The early levers are weak and
will bend and hang up as they wear.
Dexter 10" X 1 1/2"
The magnet wires for the early model round magnets are white and the late model oval magnets are yellow.
Hayes 10" X 1 5/8"
The magnet wires for the early model round magnets are red and the late model oval magnets are green.
AL-KO 10" X 2 1/4"
It will have light green wires.
Hayes 10" X 2 1/4"
The early model round will have red wires and the late model will have oval green wires.
Dexter 10" X 2 1/4"
It uses green wires.
Fayette 10" X 2 1/4"
The round magnets will have white wires (obsolete).
AL-KO 12" X 2"
It will have white wires.
Hayes 12" X 2"
The early model round magnet will have red wires, the late model will be an oval magnet with white wires.
Dexter 12" X 2"
It will have white wires.
Dexter Centerline 12" X 2"
The 4.5K axles will have red orange wires, the 6/7K axles will have red wires (obsolete for both sizes).
Technical
Magnets can be identified by the color of the wire used
B-26
BEARING PROTECTOR INSTRUCTIONS
Instructions for Bearing Protector
Before Installation
Installation Guide
Removal Guide
1. Inspect existing bearings and seals by removing hubs and check for previous damage, corrosion and improper wear before installing
new Bearing Protectors. If damage is found
replace the worn bearings with a high quality
replacement before installing the new Bearing
Protectors.
2. The inner seals should be in good working
condition before installing the Bearing
Protectors. Be sure there is a smooth running
surface on the spindle prior to installation or
improper/premature wear could occur.
3. Thoroughly clean and remove any old grease,
moisture or dirt particles out of the hub that
could contaminate the bearings or the
Bearing Protectors prior to installation.
4. Reassemble all the components being sure to
fill the hub completely with good quality bearing grease or a #2 grade multi-purpose automotive grease lubricant.
1. Hold the new Bearing Protectors in position.
2. Using a rubber mallet drive the Bearing
Protectors into place. (If a rubber mallet is
not readily available, use a regular hammer
and a block of wood in its place.) Hold the
block of wood against the Bearing Protectors,
strike the wood with the hammer to drive the
Bearing Protectors into position.
1. Disassembly is not necessary for removing
your Bearing Protectors.
2. Using a rubber mallet, strike one side of the
Bearing Protectors lightly to start removal.
Move to the opposite side of the Bearing
Protectors and strike lightly. This will start to
loosen the Bearing Protectors. Repeat the
process until the Bearing Protectors can be
completely removed from the hub. If a rubber mallet is not readily available, use a regular hammer and a block of wood in its place.
Place the wood against one side of Bearing
Protectors. Strike the wood with hammer
lightly to start removal. Move to the opposite
side of the Bearing Protectors and strike lightly. This will start to loosen the Bearing
Protectors. Repeat the process until the
Bearing Protectors can be removed completely from the hub.
NOTE:
Do Not Mix Grease Types. Do Not Use
any other grease types not listed above or those
containing fibrous compounds.
NOTE: Never strike the Bearing Protectors
directly with the hammer or damage could
occur.
3. The Bearing Protectors should fit snuggly
within the hub. If for some reason the
Bearing Protectors cannot be driven into
place or do not fit snuggly check that the
proper diameter Bearing Protectors are being
used. If the correct size is being used, contact
your local dealer.
Information call: 1-888-785-5832 or www.tekonsha.com
NOTE: Never strike the Bearing Protectors
directly with the hammer or damage could
occur.
Technical
P/N 7809 REV B
B-27
BATTERY SWITCHES INSTRUCTIONS
Instructions for Battery Switch
Installation Guide
1. Mount with cap end (crimped end) up.
2. Mount unit in an area that is not subjected to
water rain or salt spray.
3. To minimize the possibility of accidental damage due to circuit overload, use an appropriate circuit breaker inline when wiring to the
POSITIVE (+) terminal of the battery.
4. The wire size indicated below for battery connection is a minimum requirement. To
improve the secondary battery charge rate,
increase this wire size.
5. The three terminal switch housing provides
the ground return. This eliminates the need
for a ground return wire when mounted on
the auto chassis
6. The four terminal switch has an isolated case.
This would be used when mounting on a
non-conductive material, fiberglass, wood,
etc.
www.tekonsha.com
3 Terminal Switch Model P/N 7000
AUTO CHASSIS
AUTO CHASSIS
AUTO
CHASSIS
PRIMARY
BATTERY
10 GA
WIRE
10 GA
WIRE
SECONDARY BATTERY
16 GA
WIRE
OFF
RUN
IGNITION SWITCH
START
TO AUTO ELECTRIC SYSTEM
4 Terminal Switch Model P/N 7001
AUTO CHASSIS
PRIMARY
BATTERY
10 GA
WIRE
10 GA
WIRE
16 GA
WIRE
OFF
RUN
IGNITION SWITCH
START
SECONDARY BATTERY
AUTO CHASSIS
TO AUTO ELECTRIC SYSTEM
Technical
AUTO
CHASSIS
P/N 871 REV D
B-28
NOTES
Technical
B-29
Technical
NOTES
B-30
DISTRIBUTED BY
TEKONSHA TOWING SYSTEMS
1 0 1 S p i r e s Pa r k w ay • Te ko n s h a M I 4 9 0 9 2
5 1 7 - 7 6 7 - 4 1 4 2 / F a x 5 1 7 - 7 6 7 - 4 7 0 7 / 8 0 0 - S TO P - YO U
www.tekonsha.com
P/N 95000
REV. 03

Tekonsha Catalogue

Transcription

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