Draw-Tite 5500 ACTIVATOR II BRAKE CONTROL - Manual

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
0
through 9
0
with 1
0
being
the least aggressive and 9 0 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 0 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
LEVEL
LEVEL
LEVEL
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
LEVEL LEVEL
LEVEL
LEVEL
LEVEL
LEVEL
LEVEL
LEVEL
LEVEL
LEVEL
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
CHECK AND REPAIR CONNECTIONS
REFER TO "WIRING" SECTION
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
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
NO TRAILER BRAKES, PEDAL
OR MANUAL
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