Some people look at installation instructions as a test to take after installing or assembling any given product. Others go by the adage, "When all else fails, read the instructions."

Spending a few minutes now to read and understand the installation and adjustment instructions contained in this booklet can save a lot of frustration and possible product damage later on.

ITEMS CONTAINED IN THIS PACKAGE:

(1) - Display Module
(1) - Control Module
(1) - Brake Arm Bracket Assembly Package
(1) - General Installation Hardware package
(1) - 2 Foot Length of Plastic Cable Wrap
(1) - Installation and Operation Instruction Booklet
(1) - Warranty Registration Card

For technical advice or troubleshooting call:
TOLL FREE ! 1-800-533-0306
8:00 A.M. - 4:30 P.M. EST, Monday through Friday

KEEP THESE INSTRUCTIONS
IN THE TOW VEHICLE FOR FUTURE REFERENCE

POSITIONING THE BRAKE ARM BRACKET ASSEMBLY

Upon completing the Brake Arm Bracket Assembly per the instructions included in the package, slide the bracket up the brake arm approximately 6" from the brake pedal. The higher up the brake pedal arm it can be reasonably positioned, the better. Tighten the tension screw to secure the bracket in the chosen position.

NOTE: Movement of the Bracket must be less than 2 1/4" when measured from no brakes to panic braking.

MOUNTING THE CABLE CLAMP BRACKET

Due to the various shaped dashboard configurations, the Cable Clamp Bracket will have to be bent to conform to the shape of your particular vehicle's dashboard.

Position the Bracket so that it is in line with the center of the Control Module Mounting Bracket, and the angled tab is facing upward and is clear of the edge of the dashboard. Using your fingers or a pair of pliers curve or bend the Bracket until you can mount it flat on the dashboard. Mark the location of the Bracket Mounting Holes, and drill two (2) 1/8" (0. 125) diameter holes through the material at the chosen location. Be careful not to drill through any wires or components on the other side. Mount the Cable Clamp Bracket with the two (2) 3/8" long Sheet Metal Screws provided.

MOUNTING THE DISPLAY MODULE

While the Display Module must be mounted to a solid, non-moving surface, its location is only limited to driver access to the front panel. This location is determined by the installer in conjunction with the tow vehicle owner's preference, and may be approximately 18" to the left or right of the brake pedal arm.

Mark the location of the Display Module with a pointed tool using the holes in the housing or by measuring the holes one inch (1.00) apart. Drill two 1/8" (0.125) diameter holes through the material at the chosen location, being careful not to drill through any wires or components on the other side.

WARNING: Do not drill through the Display Module Housing Mounting Holes, as the drill bit might snag on the insulation tubes inside the Display Module and cause damage to them or other components inside the housing.

Mount the Display Module using the two (2) 1 1/2" sheet metal screws and lockwashers provided.

CONNECTING THE CONTROL CABLE

The Control Cable Casing can then be routed to line up with the Cable Clamp Bracket. Choose the most direct path for the Control Cable Casing to line up with the Cable Clamp Bracket. While lazy "S" curves are acceptable, avoid sharp bends as they will cause excessive friction on the Control Cable. Mark or measure the Control Cable Casing at a point which is approximately 1/2" longer than the edge of the Cable Clamp Bracket.

Remove the Control Cable Casing from the Display Module by pulling it away from the Module. With a knife or other sharp tool, cut the Control Cable Casing at the marked location. Feed the cable into the casing, and push it back into the Display Module until it is firmly in place.

WARNING: Do not cut the Control Cable Casing without removing it from the Control Cable as you may nick the Control Cable and cause a weak point which may fracture and break in the future.

Slip the Plastic Clamp over the Control Cable Casing. Mount it with the Short Leg of the Plastic Clamp against the Cable Clamp Bracket using the hardware provided. The flat washer must be against the Plastic Clamp and the lockwasher and Hex Nut must be against the Cable Clamp Bracket. (See Page 4). Tighten the screw.

Feed the Control Cable through the hole in the Control Module Mounting Bracket. Loosen the Control Module Mounting Bracket screw and rotate the bracket until you have a straight path for the Control Cable through the Control Cable mounting bracket. ( See Page 2).

Pushing the Ball End of the Control Module into the hole of the Control module Mounting Bracket, feed the Control Cable through the Control Module. Tighten the Set Screw just enough to hold the Control Cable in position.

NOTE: The Control Module contains a Spring Loaded Piston which is provided to prevent damage to the Control Cable in the event that hydraulic pressure is lost in the tow vehicle's braking system.

A second Cable Clamp and 3/8" long sheet metal screw is provided in the package. It is used to stabilize the center of the Control Cable Casing for long runs and hold it to the dashboard. It is mounted by drilling a 1/8" (0. 125) diameter hole in the dashboard.

WIRING THE DISPLAY MODULE

If this is a new installation, the minimum wire gauges are as follows:

2 and 4 brakes - 14 gauge wire 6 brakes - 12 gauge wire. (Use stranded wire only) .

If your vehicle has been pre-wired at the factory with a trailer towing package and a harness, wire the display module per the tow vehicle manufacturer's instructions and proceed to step #4.

If you are replacing any brand of brake control, the wiring used for that control may be used to wire the Display Module. Be sure to check the color codes of the wires and be sure of their final destinations.

WARNING: The Display Module must be wired to a 12 volt negative ground system only! Reversal of the red (battery) and white (ground) wires will destroy the electronics of the Display Module. Do not use the accessory or fuse panel in the tow vehicle for any connections to the Display Module, as this could cause damage to the existing wiring or other components of the tow vehicle.

NOTE: The use of insulated, solderless, crimp-on butt connectors is recommended for all wiring. Loose connections may result in intermittent operation or no trailer brakes. When passing wire through sheet metal, always go through an existing grommet, add a grommet, or use silicon rubber to insulate the wire from the hole.

Route all wires as far away from the radio, C.B., or cellular telephone antenna as possible to reduce noise.

1. WHITE WIRE (GROUND)

Using the appropriate hardware, connect the white wire (ground) to the negative (-) terminal of the battery.

WARNING: Units which are not grounded to the negative (-) terminal of the battery may not operate, or may operate intermittently.

2. RED WIRE (BATTERY)

Mount a 20 amp auto-reset circuit breaker as close to the positive (+) battery terminal as possible. Using the appropriate hardware, connect the "BATT" side of the circuit breaker to the positive (+) battery terminal. Connect the red wire (battery) to the "AUX" side of the circuit breaker.

3. BLUE WIRE (BRAKES)

Connect the blue wire (brakes) to the brake wire terminal on the tow vehicle's trailer connector.

4. After all the wire connections have been made, bundle the wires together: Cover the wires by rolling the Plastic Cable Wrap, which is provided, around the wires making a tight cover for them. Cut any excess Plastic Cable Wrap with a sharp knife or scissors, being careful not to nick the insulation of the wires.

Turn the Output control located on the front of the display Module to the full clockwise (maximum) position.

Plug the trailer and tow vehicle together at the connector: The Continuity L.E.D. should light, indicating that it senses the trailer magnets. If it does not light, check the troubleshooting chart in the back of these instructions.

Being careful not to move the tow vehicle brake pedal, make sure the Ball End of the Control Module is seated in the large hole of the Control Module Mounting Bracket. Grasp the Control Cable with your fingers and pull on it where it exits the Control Module until the Ammeter Display just turns on.

Release the cable until the Ammeter Display just turns off. Tighten the set screw with the small Allen Wrench provided.

Cut off the excess Control Cable approximately 1" from where it exits the Control Module.

To facilitate removal of the Control Module for service or when you do not have a trailer in tow, a slot has been provided in the Control Module Mounting Bracket.

It is recommended that the Control module be removed when you are not towing your trailer for extended periods of time. This will prevent excess wear on the mechanical portions of the Ultima and shut off the ammeter.

ADJUSTING AND TESTING OF THE SYSTEM

NOTE: All tests must be performed with the tow vehicle engine running and the trailer electrically connected to the tow vehicle.

The Continuity L.E.D. should be illuminated whenever the trailer and tow vehicle are electrically connected. If not, a problem is indicated. Refer to the Troubleshooting Chart in the back of these instructions.

With the "Green" Continuity Indicator illuminated, each time the tow vehicle brakes are applied or pressure is exerted on the Manual Button, a digital reading, in amperes, should appear on the front of the Display Module.

If there is no digital display and/or there is only a decimal point on the Ammeter; a problem is indicated and the Display Module should be returned for service.

A reading of 88.8 would indicate there is a short circuit somewhere which must be corrected before proceeding with any tests or moving the vehicles. If this reading occurs while driving, you will not have trailer brakes and the problem must be corrected to insure safe travel.

With the "Output Control" set at "maximum" (fully clockwise) and the "Green" Continuity Indicator illuminated, fully depress the Manual Button. Since each magnet will draw 2.5 to 3.0 amps, the following readings are normal:

2 brakes = 5 to 8 amperes
4 brakes = 10 to 14 amperes
6 brakes = 15 to 20 amperes

NOTE: Because of system variances, ammeter readings may vary slightly from the chart. If large variances occur, (2 to 3 ampere difference) a check of the system must be made before continuing. Pulling the breakaway switch with the trailer and tow vehicle connector engaged may damage the controller, and is not recommended.

A simple method to check the operation of any magnet is with a compass. Place the compass near the bottom center point of the wheel of the magnet to be tested and have someone activate the brakes. The needle of the compass should deflect indicating the magnet is energized. If a problem is indicated, repairs should be implemented before proceeding with any tests or moving the trailer.

Once it has been established that the electrical system is complete and operating, note the reading for your particular tow vehicle/trailer combination and record it for future reference.

1. Press the Manual Button all the way inward until it stops.

2. Turn the Output Control counterclockwise until the ammeter reads:

3.5 amps for 2 brakes
7.0 amps for 4 brakes
10.5 amps for 6 brakes

3. Release the Manual Button. The Digital Display should turn off. If it does not, check the Troubleshooting Chart.

4. With this adjustment made, tow the trailer on a dry, hard surface at 20- 25 miles per hour.

5. Press the Manual Button fully on.

A. If the trailer brakes do not lock up, rotate the Output Control clock wise, and increase the Digital Readout by increments of 0.5 amperes until they do.

B. If the trailer brakes lock up, rotate the Output Control counter clockwise, and decrease the Digital Readout by increments of 0.5 amperes until they do not.

NOTE: If one or more of the trailer brakes lock up with digital readings that are less than 2.5 amperes, the problem is a mechanical malfunction and must be corrected before any adjustments can be made.

The main cause for this problem is loose trailer brake adjustment. New trailers must be adjusted after the first 300 miles of operation, when the brake shoes and drums have been "seated". At all times, electric brakes should be adjusted at 3,000 mile intervals or as use and performance requires. To perform correctly, electric brakes must be kept in adjustment. Check with your electric brake manufacturer for recommended procedures.

6. Repeat steps 5-A or 5-B until maximum digital readings are obtained without trailer wheel lockup. This is the "optimum" adjustment. While the "optimum" reading will be a matter of individual preference by the tow vehicle driver as to how "hard" or "soft" the brakes feel when applied, it should always be less than lockup. Skidding wheels can cause loss of directional stability of the trailer and possibly the tow vehicle as well.

Under normal driving and stopping conditions, if the trailer brakes seem to be lighter than usual, and/or the Ammeter readings are lower than usual, a potential problem may be indicated. Do not compensate for the lower reading by increasing the amperage with the Output Control until the reason for the discrepancy has been established. It is best to pull off of the road and check the system.

A simple test of the electrical braking system is possible at any time. Safely park the vehicles and turn the Output adjustment to the "maximum" setting (fully clockwise). Check to see that the "Green" Continuity Light is illuminated and fully depress the Manual Button. The Ammeter reading should be the same as the reading that was noted above before any adjustments were made. If the readings are not the same, a problem is indicated. The problem should be diagnosed and corrected before moving the vehicles. If everything is correct, turn the Output Adjustment counterclockwise until you have reached the "optimum" setting you obtained during the adjustment phase and proceed.