Reese 83500 BRAKEMAN DIGITAL BRAKE CONTROL User Manual

Instructions for the installation and operation of, Controls, Tools required

INSTRUCTIONS FOR THE INSTALLATION
AND OPERATION OF

ELECTRONIC TRAILER
BRAKE CONTROL FOR
2, 4, 6 & 8 BRAKE
SYSTEMS

IMPORTANT: READ AND
FOLLOW THESE INSTRUC-
TIONS CAREFULLY. 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 or

¹⁄₄" Nut Driver

MATERIAL REQUIRED:

10 Ga. wire
30 Amp auto-reset circuit breaker
Assorted ring terminal & butt con-
nectors
4" cable ties (6-10)

CONTROLS

OUTPUT CONTROL

The Output Control establishes the maximum amount of
power available to the trailer brakes.

As the Control is rotated up 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 during initial setup,
when trailer load changes, when different trailers are used
or to adjust for a change in road conditions.

The Output setting is shown on the digital display when a
trailer is connected and the brake pedal is pressed or the
Manual Control is actuated.

The Output setting is shown as 0 through 10 with 0 being
the minimum and 10 the maximum.

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 trailer brake aggressiveness.

The trailer brakes become more aggressive as the switch
is moved toward the front of the tow vehicle.

To view the Sync setting on the display, press the brake

OUTPUT CONTROL

OUTPUT / SYNC

DISPLAY

MANUAL CONTROL

SYNC CONTROL

MORE OUTPUT

LESS OUTPUT

PUSH TO
APPLY BRAKES

MORE AGGRESSIVE BRAKING

LESS AGGRESSIVE BRAKING

pedal (trailer must be connected) and move the Sync Control
slightly. The display will change to the Sync mode.

The Sync setting is shown as 1

through 9

with 1

being

the least aggressive and 9

being the most aggressive.

The Sync adjustment has no effect on the manual control.

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 during initial setup and in situations where 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 Output setting will be shown on the display and can be
adjusted when using the Manual Control.

The Manual Control activates the tow vehicle and trailer stop-
lights.

SETUP

Preliminary Adjustments

With the trailer connected press and hold the brake pedal,
the Display will show the Output setting.

Adjust to 2.0 by turning the control up or down as needed.

While still holding the brake pedal move the Sync Control
slightly, the Display will change to the Sync setting.

Adjust to 4

by sliding the Sync Control ahead or back as

necessary.

TEST DRIVE

In an open area, such as a large parking lot, drive forward
and apply the trailer brakes using the Manual Control.

If the trailer brakes are weak adjust the Output Control up.

If the trailer brakes jerk or lockup adjust the Output Control
down.

Repeat this step until firm braking is felt with out jerking or
lockup.

Once the Output is set, drive forward and press the brake
pedal, the tow vehicle and trailer should make a smooth stop.

If the stop seems slow and more aggressive braking is
desired, move the Sync Control rearward while holding the
brake pedal.

If the stop seems too aggressive adjust the Sync Control
rearward while holding the brake pedal.

After making a Sync adjustment the Display will show the
setting until the brake pedal is released.

Make several stops at various speeds and adjust the Sync
until stops are smooth and firm. Slight adjustment of the
Output Control may also be desirable.

NOTE: If any problems occur during Setup refer to the
Trouble Shooting section of these instructions.

DIGITAL DISPLAY

The Digital display shows the Output setting when the
control is activated. It is used to setup and monitor the
Brake Control and can be used when trouble shooting.

SINGLE DECIMAL
CONTROL ACTIVATED
NO TRAILER CONNECTED

OUTPUT DISPLAY
CONTROL ACTIVATED
TRAILER CONNECTED

SYNC DISPLAY
BRAKE PEDAL PUSHED
SYNC CONTROL ACTIVATED
TRAILER CONNECTED

OVER LOAD DISPLAY
SHORTED OR OVER LOADED
BRAKE CIRCUIT
SEE TROUBLE SHOOTING GUIDE

ERROR DISPLAY
INTERNAL CONTROL ERROR
SEE TROUBLE SHOOTING GUIDE

LEVEL

DISPLAY MODES

USAGE TIPS

Light pressure on the brake pedal will activate the trailer's
brakes with no effect on the tow vehicle's brakes. This is
useful for gradual slowing on steep grades or before stops.

Periodic adjustment of the Sync and Output controls
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".

When Towing (in most applications) with Hazard Flashers
on the Digital Display will flash with the Hazard Flashers. If
the Brake Control is set aggressively pulsing may be felt in
the trailer brakes.

Installation of a Pulse Preventor will isolate the brake con-
trol from the flashers and eliminate the flash/pulse situa-
tion.

TROUBLE SHOOTING GUIDE

WITHOUT TRAILER CONNECTED

WITH TRAILER CONNECTED

TEST WITHOUT TRAILER FIRST

CONDITION

DISPLAY

PROBABLE CAUSES

POSSIBLE SOLUTION

DECIMAL ONLY

BLANK

PEDAL

MANUAL

OUTPUT SETTING

FLASHING OL

ERROR

DECIMAL ONLY

OUTPUT SETTING

FLASHING OL

ERROR

OUTPUT SETTING

LEVEL

BLANK

LEVEL

DECIMAL ON ALL THE TIME

DECIMAL POINT DOES NOT LIGHT
WHEN BRAKE PEDAL OR MANUAL
CONTROL IS USED

NO POWER TO CONTROL, NO GROUND,
REVERSED BLACK AND WHITE WIRES,
CIRCUIT BREAKER BLOWN

NO CONNECTION OR INCORRECT
CONNECTION AT STOPLIGHT SWITCH,
BLOWN FUSE IN STOPLIGHT CIRCUIT

CHECK AND REPAIR CONNECTIONS
REFER TO "WIRING" SECTION

LOCATE AND CORRECT SHORT

RETURN UNIT TO DEALER FOR
EVALUATION

CONFIRM TRAILER CONNECTOR
TERMINAL POSITIONS

RETURN UNIT TO DEALER FOR
EVALUATION

CHECK AND CORRECT CONNECTOR
WIRE POSITIONS

CONFIRM CONNECTION TO TRAILER
CONNECTOR, CONFIRM CONNECTOR
TERMINAL POSITIONS, CHECK TRAILER

TROUBLE SHOOT TRAILER BRAKE
CIRCUIT PER BRAKE MANUFACTURER'S
INSTRUCTIONS

CHECK AND REPAIR CONNECTIONS
REFER TO "WIRING" SECTION,
CHECK STOPLIGHT CIRCUIT

RED WIRE CONNECTED TO THE WRONG
SIDE OF THE STOPLIGHT SWITCH OR
TO WRONG SWITCH (CRUISE CONTROL)

BRAKE CONTROL UNIT MISWIRED

SHORT IN BLUE WIRE CIRCUIT

INTERNAL BRAKE CONTROL PROBLEM

NO CONNECTION BETWEEN BRAKE CONTROL
AND BRAKES - BLUE WIRE CIRCUIT

MISWIRED TRAILER CONNECTOR

DECIMAL POINT DOES NOT LIGHT
WHEN BRAKE PEDAL IS PUSHED
DOES LIGHT WITH MANUAL

DISPLAY SHOWS OUTPUT
SETTING

DISPLAY SHOWS OL WHEN
ACTIVATED

DISPLAY SHOWS Er

NO TRAILER BRAKES, PEDAL
OR MANUAL

SHORT OR OVERLOAD IN TRAILER BRAKES

NO TRAILER BRAKES, PEDAL
OR MANUAL

INTERNAL BRAKE CONTROL PROBLEM

WEAK OR NO TRAILER BRAKES

MISWIRED TRAILER CONNECTOR

TRAILER BRAKES ON ALL THE
TIME

MISWIRED TRAILER CONNECTOR

Towing Products
47774 Anchor Court West
Plymouth, MI 48170

TOWING PRODUCTS 2003

PRINTED IN CHINA

05500-037 1 of 3 rev. 2/6/03

05500-037 2/6/03 English 3/6/03 2:05 PM Page 1