Prodigy® RF Electronic Brake Control

READ THIS FIRST

Read and follow all instructions carefully before installing or operating the Prodigy RF. Keep these instructions with the Brake Control for future reference.

Components of Prodigy RF

The Prodigy RF system includes the following main components:

• A. Power Knob: Controls the power output to the trailer brakes.
• B. Boost Button: Engages an enhanced braking response.
• C. Manual Override: Allows manual application of trailer brakes.
• D. Display: Shows system status, settings, and troubleshooting codes.
• E. Connector to Auxiliary Power Port: Connects the Hand Held Unit to the vehicle's power source.
• F. 7-Way Cable to Tow Vehicle: Connects the Power Module to the tow vehicle's trailer connector.
• G. Connection to Trailer: Connects the Power Module to the trailer's brake system via the 7-Way connector.

Important Facts to Remember

• ⚠️ WARNING: The Prodigy RF may operate with reduced performance if the Remote Hand Held Unit is removed or disconnected while the trailer is in use.
• ⚠️ WARNING: Do not mount or activate RF generating items (cell phones, two-way radios) within 12 inches of the Hand Held Unit or Power Module.
• The Prodigy RF employs an inertial sensor that senses deceleration to generate a proportional braking output.
• The Prodigy RF will "HOLD" your trailer with 25% of the power setting when the vehicle is at a standstill with the brake pedal applied for longer than 5-7 seconds.
• The Prodigy RF will brake proportionally in reverse, applying appropriate brake voltage based on deceleration.
• ⚠️ WARNING: The Gross Combined Weight Rating (GCWR) must never exceed the vehicle manufacturer's recommendation.
• ⚠️ CAUTION: This control is not designed for use with electric-hydraulic trailer brake systems.
• ⚠️ CAUTION: Do not submerge or immerse the Prodigy RF in water.
• For Technical Assistance and Warranty Information, call 1-888-785-5832 or visit www.tekonsha.com.

Installation Guide: Trailer Mount Power Module

Mounting Instructions

⚠️ WARNING: The Prodigy RF Power Module must be securely mounted to the trailer frame. Failure to install the Power Module within these constraints may cause impaired performance.

The Power Module can be mounted to any suitable surface on the trailer frame. The module cover should be approximately level, within ±5 degrees, and above the trailer frame rail. The preferred mounting location is on the side of the trailer frame rail with the 8-foot cable towards the tow vehicle.

Mounting Steps:

1. Select a location so that the Power Module's cover is in the UP direction.
2. Use the four 1/4-14 x 1-1/4 self-drilling screws (provided) to drill into the trailer frame. Snug screws securing the Power Module. Tamper-resistant washer head screws may be used for added security.
3. Secure the excess 7-Way tow vehicle and trailer wiring.

⚠️ CAUTION: Use of different screws may damage the Power Module or may not provide sufficient mounting.

⚠️ CAUTION: Do not mount in a concealed location, or inside a metal part of the trailer. Do not place inside a utility box mounted on the trailer.

⚠️ CAUTION: Do not mount in a location that will interfere with a load-equalizing hitch.

Connecting Power Module

Your Prodigy RF Power Module has a molded Bargman® 7-Way cable that plugs into the tow vehicle. Refer to the Wiring Diagram for pin locations and functions. This connection supplies all power and signals to both the Power Module and the trailer. The trailer's 7-Way cable connects directly to the 7-Way connector on the rear of the Power Module. No additional wiring is necessary on the trailer.

⚠️ WARNING: The tow vehicle must be capable of providing 12V @ 20A for electric brake applications, supporting up to 6 brakes (3 axles).

⚠️ CAUTION: The battery charge to the trailer may be temporarily disconnected (approximately 5 minutes) during braking if the total current to the trailer (battery charge and electric brake) exceeds 20 Amps. This allows for full brake power without exceeding the tow vehicle's wiring capacity.

ℹ️ NOTE: Some factory-wired tow vehicles disconnect the battery charge output in the 7-Way connector when the ignition is turned off. This will turn off the Power Module, and the Hand Held Unit will display "n.c." (not connected).

Wiring Diagram

The 7-Way trailer connector has the following pin functions:

• Pin 1: Common Ground
• Pin 2: Electric Brake
• Pin 3: Tail & License
• Pin 4: Battery Charge
• Pin 5: Left Stop & Turn
• Pin 6: Right Stop & Turn
• Pin 7: Center Auxiliary

Remote Hand Held Unit

Plug the Hand Held Unit into any suitable 12V Auxiliary Power Port in the vehicle. Ensure the Remote Hand Held Unit is within easy reach of the operator and do NOT operate the unit while it is disconnected.

Automatic Leveling of the Sensor

The Prodigy RF will automatically acquire the proper level setting of the tow vehicle and trailer combination during the pairing operation.

Pairing Instructions

Synchronization of the Remote Hand Held Unit to the Power Module:

1. Connect the trailer to the tow vehicle.
2. Plug the Power Module's 7-Way cable into the tow vehicle.
3. Ensure the trailer's 7-Way connector is disconnected from the Power Module.
4. Start the vehicle's engine. (Some vehicles require the ignition to be ON to supply power to the 7-Way connector or Auxiliary Power Port).
5. Plug the Remote Hand Held Unit into an auxiliary power source within easy reach of the operator.
6. Turn the Power Knob to the minimum position. The display will show flashing "0.0".
7. Fully depress and hold both the MANUAL OVERRIDE and BOOST BUTTON. The display will cycle from "P.5" to "P.A".
8. Once "P.A" is achieved, release the Manual Override and Boost buttons.
9. Press and hold the brake pedal until the display shows flashing "0.0" for correct pairing.
10. Set the Power Knob to a position greater than minimum. The display will now flash "n.c." (not connected).
11. Re-connect the trailer's 7-Way connector to the Power Module. The display should now show ".c." (connected).

ℹ️ NOTE: To properly identify your trailer during pairing, the 7-Way trailer plug must be disconnected from the Power Module.

Display Readings after Connecting the Prodigy RF

Once the units are connected and successfully paired, the two-digit display will show:

• Flashing "n.c.": Initial power to the Hand Held Unit without pairing, Power Module not powered, or paired but trailer not connected.
• "n.c.": Power to Prodigy RF with trailer connected and Boost feature not engaged.
• "n.c." with right decimal point: Boost feature engaged.
• "n.c.": Manual Override activated without trailer connected.
• "5.4" (example): Manual Override activated (with trailer). This value indicates a hypothetical power output, set using the power knob, ranging from 0.0 to 13 volts, representing voltage output to electric brakes.
• (Blank Display): Display will be blank during power-saving mode (no motion or braking activity for at least 2 hours).

Adjusting the Power to the Trailer Brakes (Prior to setting Boost)

Once the Power Module is mounted and paired to the Hand Held Unit, set the power needed to stop the trailer during a braking event.

1. Connect trailer to tow vehicle.
2. Verify the Power Module and Hand Held Unit have been paired.
3. Verify all tow vehicle and trailer cables are properly connected.
4. ⚠️ CAUTION: Verify proper operation of all tow vehicle and trailer lights prior to towing.
5. With the engine running and the Manual Override fully depressed, set the Power Knob to indicate approximately "6.0", then release the Manual Override.
6. Drive the tow vehicle and trailer on a dry, level paved surface at 25 mph and fully apply the Manual Override.
7. If trailer brakes lock up: Turn power down using the power knob.
8. If braking was not sufficient: Turn power up using the power knob.
9. Repeat step 6 until power is set just below wheel lock-up or at a force sufficient for maximum braking power.
10. Using the brake pedal, make a few low-speed stops to check the power setting. Trailer braking is initiated and terminated via signals on the trailer wiring (Left/Right Turn and Stop). Trailer braking will cease when the brake pedal is released.

Boost Setting

The Boost button allows for a more aggressive setting for your trailer brakes, available in three levels: [b1], [b2], [b3]. Each level increases the sensitivity of the Brake Control's inertial sensor, enhancing trailer brake participation during a braking event.

Pressing the boost button displays the current setting. Boost advances to the next level with subsequent presses. Five seconds after setting the boost level, the display will show "n.c." indicating Boost On by the right-most decimal.

Boost Level Examples:

• Boost Off ([.c]): Power starts at zero and increases with deceleration.
• Boost Level 1 ([b1]): Power starts at approximately 13% of the power setting and increases with deceleration.
• Boost Level 2 ([b2]) or Level 3 ([b3]): Power starts at approximately 25% of the power setting and increases with deceleration.

When to Use Boost:

• When you want the trailer braking to "LEAD" the tow vehicle's braking.
• When towing a full versus an empty trailer.
• When experiencing degraded brake performance (electric brakes may require manual adjustment; see Appendix A).

ℹ️ NOTE: Boost is not intended to replace trailer brake adjustment or repair.

Typical Boost Settings For Optimal Performance (with properly adjusted trailer brakes*)

* Increased Boost setting may be needed if trailer brakes are worn; see Appendix A or a dealer for brake adjustment or repair.

Select your boost setting based on your towing situation, driving preference, and the condition of your trailer brakes.

ℹ️ 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 the 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 the 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. When the power is set correctly, you should feel unified braking between the trailer and tow vehicle.

Reverse

When backing a trailer, you can cancel "BOOST" and "HOLD" for a period of three minutes. This is accomplished by pressing the boost button continuously for five seconds with the brake pedal depressed. The display will indicate "n.c.". (If "boost" was active, the right-hand decimal point will also be on.) After three minutes, the "BOOST" and "HOLD" features will automatically return to your previous settings.

ℹ️ NOTE: Returning to your previous settings prior to three minutes can be accomplished by pressing the boost button.

Sleep Mode

To conserve power, the Prodigy RF system will enter a sleep mode 2 hours after there has been no movement or braking activity on the Power Module or Hand Held Unit.

Wake Up

1. Pressing the brake pedal in the tow vehicle or connecting/disconnecting the trailer from the Power Module will wake up both the Power Module and Hand Held Unit.
2. The Hand Held Unit will wake up by any activation of the Manual, Power, or Boost buttons. However, if the Power Module does not have power or is disconnected, the Hand Held Unit will flash "n.c." then return to sleep mode.

Troubleshooting Chart

Situation: Flashes 2 times per second

Probable Cause: Trailer is connected and Prodigy RF loses connection to battery ground.

Situation: Flashes 2 times per second

Probable Cause: Prodigy RF "sees" an overload condition during operation.

Situation: Flashes 2 times per second

Probable Cause: 1. Prodigy RF sees brake wire short during idle condition. 2. Use of some test lights or non-Tekonsha testers can cause this problem.

Situation: Flashes continuously

Probable Cause: 1. Power Module not connected to tow vehicle. 2. Trailer connector disconnected or corroded. 3. Key off or Loss of Battery Power from tow vehicle. 4. Trailer connected with open circuit on the brake line. 5. Loss of trailer brake magnet ground. 6. Loss of RF Communications, signal, or interference. 7. Unit not paired or improperly paired.

Situation: No display with manual or pedal activation.

Probable Cause: 1. Loss of power to Prodigy RF Hand Held Unit. 2. Loss of Ground to Prodigy RF Hand Held Unit. 3. Sleep mode. To wake up, press manual or boost button. 4. Blown fuse in Hand Held Power Plug.

Situation: (Blank Display)

Probable Cause: Power control set to zero.

Situation: No Braking Flashes Continuously

Probable Cause: Power interruption while brake pedal is depressed.

Situation: "P.L."

Probable Cause: 1. Intermittent power connection in 7-Way connector. 2. Power is applied while the manual or brake pedal is depressed.

Situation: "P.S" to "P.A" (Pairing mode)

Probable Cause: 1. Pairing mode. 2. Trailer connected while in pairing mode. Temporarily disconnect trailer from Power Module while "P.A" is flashing. 3. Brake pedal not depressed during pairing. 4. Unable to recognize Left / Right Turn and Stop Signals.

Situation: "P.A" Flashing continuously

Probable Cause: 1. Unable to pair.

Appendix A: Trailer Brake Adjustment

Brakes should be adjusted after the first 200 miles of operation (when shoes and drums have "seated") and at 3000-mile intervals, or as use and performance requires. Follow these steps:

1. Jack up the trailer and secure it on adequate capacity jack stands. Follow trailer manufacturer's recommendations for lifting and supporting the unit. Check that the wheel and drum rotate freely. ⚠️ WARNING: Do not lift or support the 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. Using 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. ℹ️ NOTE: With drop-spindle axles, a modified adjusting tool with about an 80-degree angle should be used.
4. 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 this procedure on all brakes. ⚠️ WARNING: Never crawl under your trailer unless it is resting on properly placed jack stands. Follow the trailer manufacturer's 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.

Appendix B: FCC Information

Contains Transmitter Module. FCC ID: TBF-FREESTAR.

⚠️ WARNING: This device complies with Part 15 of the FCC Rules. Its operation is subject to the following conditions: (1) This device may not cause harmful interference, and (2) This device must accept any interference received, including interference that may cause undesired operation.

To comply with FCC RF exposure requirements for mobile transmitting devices, this transmitter should only be used or installed at locations where there is at least 20 cm separation distance between the antenna and all persons.

Appendix C: Patent Information

Covered by one or more of the following: U.S. PAT. 5741048, 6012780, 6068352, 6445993, 6615125, AU 716150, CA 2225644. Other patents pending.

P/N 4747 REV A ©2008 Cequent