Draw-Tite 5100 ACTIVATOR BRAKE CONTROL - Manual

+ SYNC -
OUTPUT
ACTIVATOR
OUTPUT
ACTIVATOR
OUTPUT
CONTROL
More Output
Less Output
OUTPUT
INDICATOR
SYNC CONTROL
MANUAL
CONTROL
More Aggressive Braking
Less Aggressive Braking Push to Apply
Trailer Brakes
CONTROLS
OUTPUT CONTROL
The output control is located on the front of the brake
control unit at the top left side.
The output control establishes the maximum amount of
power available to the trailer brakes.
As the setting is moved to the left more power will be
available to the brakes when the brake pedal is
pressed or the manual control is used.
The output control would be adjusted when trailer load
changes, when different trailers are used or to adjust
for a change in road conditions.
SYNC CONTROL
The sync control is located on the left side of the brake
control unit, forward of the mounting bracket. The sync
control adjusts brake aggressiveness or the time it takes
to reach the full output set by the output control when the
brake pedal is pressed.
The sync adjustment has no effect on the manual control.
The brakes become more aggressive as the switch is
moved toward the front of the tow vehicle.
The sync control would be adjusted for individual driver
preference or changing road conditions.
MANUAL CONTROL
The manual control is located on the front of the brake
control unit at the right side.
The manual control only applies the trailer brakes and
would be used in situations when it is desirable to reduce
speed slowly.
When the manual control is pushed to the left the control
begins to apply the trailer brakes. The further to the left it
is pushed the harder the brakes are applied until the
maximum set by the output control is reached.
The manual control activates the tow vehicle and trailer
stoplights and the output indicator on the control unit.
OUTPUT INDICATOR
The red indicator light on the front of the control unit will
glow when brakes are applied either by the brake pedal
or the manual control (with or without a trailer attached).
The indicator will start dim and glow brighter as output
increases.
The indicator light will also help confirm proper installation.
SET UP
1. With a trailer connected, set the sync control half
way between + and -. Starting with the output
control in the lowest position (all the way right) roll
forward slowly and stop. If no trailer braking is felt
adjust the output control slightly to the left. Repeat
this process until firm trailer brakes are felt. If the
trailer brakes lock-up or jerk adjust the output
back to the right slightly.
2. Move the sync control back (toward the driver) to
about 1/4 of the distance between + and -.
3. Test drive making several stops. Adjust the sync
control until stops are smooth and firm. Slight
adjustment of the output control may also be
desirable.
Setting the brake control too aggressively
could cause brake pulsing when towing
with hazard flashers on. If such settings
are necessary, a pulse preventor can be
used.
4. Have someone watch the stoplights while the
manual control is activated to make sure the stop-
lights on both the tow vehicle and trailer are work-
ing.
Note: If any problems occur during set up refer to
the Trouble shooting section of these instructions.
USAGE TIPS
Light pressure on the brake pedal will activate the
trailer’s brakes with little or no effect on the tow vehi-
cle’s brakes. This is useful for gradual slowing on
steep downhill grades or before stops.
INSTRUCTIONS FOR THE INSTALLATION
AND OPERATION OF
ELECTRONIC TRAILER BRAKE CONTROL FOR
2 AND 4 BRAKE SYSTEMS
IMP0RTANT: READ AND
FOLLOW THESE
INSTRUCTIONS CARE-
FULLY. KEEP THESE
INSTRUCTIONS IN YOUR
TOW VEHICLE FOR
FUTURE REFERENCE.
THIS PACKAGE INCLUDES:
(1) Brake Control Unit
(1) Mounting Bracket
(4) Mounting Screws
(1) Wire Tap Connector
(1) Warranty Card
TOOLS REQUIRED:
Assorted end wrenches
Drill with 1/8” bit
Wire connector crimp tool
Probe type circuit tester
Wire cutter/stripper
Screwdriver
MATERIAL REQUIRED:
12 Ga. or larger wire
20 Amp auto-reset circuit breaker
Assorted ring terminals
& butt connectors
4” cable ties (6-10)
+ SYNC
–
Periodic adjustment of the Sync and Output con-
trols may be necessary to correct for changing road
conditions, trailer loading, brake wear and/or driver
preference. On some vehicles, operating the brake control’s manual
control will not disengage “Cruise Control.”
TROUBLE SHOOTING GUIDE
PROBLEM LIGHT POSSIBLE CAUSES SOLUTION
TRAILER BRAKING IS DELAYED ON INCORRECT SYNC ADJUSTMENT ADJUST TO MORE AGGRESSIVE POSITION
TRAILER BRAKES COME ON TOO FAST ON INCORRECT SYNC ADJUSTMENT ADJUST TO LESS AGGRESSIVE POSITION
TRAILER BRAKES ARE WEAK ON INCORRECT OUTPUT ADJUSTMENT ADJUST FOR MORE OUTPUT
TRAILER BRAKES COME ON TOO HARD ON INCORRECT OUTPUT ADJUSTMENT ADJUST FOR LESS OUTPUT
NO TRAILER BRAKES - PEDAL OR MANUAL OFF NO POWER TO UNIT THRU BLACK “BATTERY +” WlRE CHECK CONNECTIONS AT: BATTERY,
OPERATION CIRCUIT BREAKER, BRAKE CONTROL
OUTPUT ADJUSTED TOO LOW RE-ADJUST (SEE SET UP)
NO TRAILER BRAKES - PEDAL OR MANUAL ON NO CONNECTION TO TRAILER BRAKES THRU BLUE CHECK TRAILER CONNECTOR CONTACTS
OPERATION (BRIGHT) “BRAKE” WIRE CHECK WIRE CONNECTIONS (SEE WIRlNG)
TRAILER OR TRAILER BRAKES NOT GROUNDED CHECK TRAILER AND BRAKE GROUNDS
NO TRAILER BRAKES USING BRAKE PEDAL OFF NO CONNECTION AT STOPLIGHT SWITCH THRU RED CHECK STOPLIGHT CONNECTION
MANUAL OPERATION WORKS (PEDAL) “STOPLIGHT” WIRE (SEE WIRlNG STEP 8)
ON
(MANUAL)
TRAILER BRAKES LOCKED ON WHEN RED “STOPLIGHT” WlRE CONNECTED TO WRONG CHECK CONNECTION (SEE WIRlNG STEP 8)
CONNECTED TO CONTROL ON SIDE OF STOPLIGHT SWITCH OR TO BATTERY +
BREAK-AWAY SWITCH ACTIVATED CHECK SWITCH AND CORRECT
TRAILER BRAKES SEEM TO BE WORKING DIM OR FAULTY WHITE “GROUND” WIRE CONNECTION CHECK CONNECTIONS
FLICKERS
WEAK OR INCONSISTANT TRAILER BRAKES DIM OR SHORT IN BLUE “BRAKE” WlRE CIRCUIT LOCATE SHORT & CORRECT
FLICKERS SHORT IN TRAILER BRAKE CIRCUIT LOCATE SHORT & REPAIR
BRAKE CONTROL OVERHEATS, SMELLS DIM BLACK “BATTERY +” WIRE & WHITE “GROUND” BRAKE CONTROL UNIT DESTROYED
HOT, LOW OR NO BRAKE OUTPUT WIRE CONNECTIONS REVERSED CORRECT WIRING & REPLACE UNIT
TOWING PRODUCTS 47774
Anchor Court West
Plymouth, MI 48170
© TOWING PRODUCTS 2003
PRINTED IN CHINA
05100-037 1 of 3 rev. 1/21/03
Note: A standard voltmeter will not show true output voltage.
05100-037 1/21/03 English 3/6/03 2:00 PM Page 1