Pro Series 80500 POD FOR 1 AND 2 AXLE TRAILERS - Manual

Electronic Brake Control
For 2 to 4 brake applications
Components of the Brake Control
A. Power Knob
B. Manual Slide Knob
C. Bracket Mounting Holes
D. Bi-Colored Light
Important Facts to Remember
1. Do not mount or activate RF generating items
(cell phones, two way radios) near (less than
12") the Brake Control.
2. CAUTION Reversing the connection to a
breakaway battery on the trailer will destroy the
Brake Control.
3. CAUTION Disconnect trailer plug from the
tow vehicle prior to testing a breakaway switch
or you may 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.
• Flashing RED or OFF when trailer is not con-
nected.
5. The GREEN light draws 10 milliamperes of cur-
rent from tow vehicle. It would take over 5,000
hours to drain the tow vehicles battery.
6. WARNING The Gross Combined Weight
Rating (GCWR) must never exceed the vehicle
manufacturers recommendation.
7. This control specfically designed for use with
electric trailer brakes.
8. For Technical Assistance and Warranty
Information call: 1-888-785-5832 or
www.tekonsha.com
READ THIS FIRST:
Read and follow all instructions carefully before
installing or operating the Brake Control. Keep
these instructions with the Brake Control for
future reference.
P/N 7760 REV G 10/03
Installation Guide
A. Mounting Bracket
B.
#6 x 3/8” Screws
C. Mounting Holes
1. CAUTION Drilling or use of longer screws
may damage unit.
2. Securely mount bracket to a solid surface.
3. Insert supplied #6 x 3/8”screws on each side
into the mounting holes.
4. Adjust Brake Control to desired position and
tighten screws until snug.
Adjusting the Power to the
Trailer Brakes
Once the control has been installed, it is necessary
to set the power needed to stop the trailer during a
braking event.
1. Connect trailer to tow vehicle.
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.
4. Drive tow vehicle and trailer on a dry level
paved surface at 25 mph and apply manual slide
knob.
✓ If trailer brakes lock up:
❑ Turn power down using power knob.
✓ If braking was not sufficient:
❑ Turn power up using power knob.
5. Repeat Step (4) until power has been set to a
point just below wheel lock up or at a sufficient
force as to achieve maximum braking power.
A
C
B
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 lever engaged
enough to cause trailer braking at a low level.
2. 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.
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. However, inability to lock
up the brakes generally indicates the need for
an inspection to determine the cause.
5. The driver may find it necessary to readjust
the power to a lower setting for extended peri-
ods of in town stop and go driving. It is
always good practice to readjust the power
when returning to highway driving.
Troubleshooting Chart
Appendix A: Trailer Brake Adjustment**
Brakes should be adjusted after the first 200 miles of
operation when the brake shoes and drums have “seated” and
at 3000 mile intervals, or as use and performance requires. The
brakes should be adjusted in the following manner:
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.
WARNING Do not lift or support trailer on any part of
the axle or the suspension system.
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.
Note: With drop spindle axles, a modified adjusting tool with
about an 80 degree angle should be used.
4. Then rotate the starwheel in the opposite direction until
the wheel turns freely with a slight lining drag.
5. Replace the adjusting hole cover and lower the wheel to
the ground.
6. Repeat the above procedure on all brakes.
WARNING 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.
Situation Probable Cause
No trailer brakes with manual knob activated.
Light is GREEN. • POWER set to minimum, adjust to a higher setting.
No trailer brakes with foot pedal depressed.
Light is GREEN. • POWER set to minimum, adjust to a higher setting.
• RED (stoplight) wire connected incorrectly.
• Bad connection on RED wire.
• Blown stoplight fuse.
Trailer braking is weak.
Light is GREEN / RED. • POWER set too low, adjust to a higher setting.
Trailer braking is weak or inconsistent
Light is OFF, Flashing RED or DIM. • Trailer is not connected to vehicle.
• Open circuit on brake line.
• Ground connection is poor.
• No POWER to unit through BLACK wire.
Trailer braking is too strong.
Light is GREEN / RED. • POWER set too high, adjust to a lower setting.
Trailer brakes locked when connected to vehi-
cle.
Light is RED. • RED (stoplight) wire connected incorrectly.
• Breakaway system employed.
• BLACK & WHITE wires reversed, control destroyed.
Light is GREEN all the time • Short from brake line to ground.
• BLACK & WHITE wires reversed, control destroyed.
D
B
A
C
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