Tekonsha Electronic Brake Control Installation and User Guide

Introduction

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

Components of the Brake Control

The brake control unit features the following components:

• A. Power Knob
• B. Boost Button
• C. Manual Slide Knob
• D. Connector (For Wiring Harness)
• E. Bracket Mounting Holes
• F. Two Digit Power Display
• G. Dash Mounting Clip Attachment Locations

Diagram Description: A visual representation of the brake control unit showing labeled components A through G.

Important Facts to Remember

• Do not mount or activate RF generating items (cell phones, two way radios) near (less than 12") the Brake Control.
• CAUTION: Reversing the connection to a breakaway battery on the trailer will destroy the Brake Control.
• CAUTION: Disconnect trailer plug from the tow vehicle prior to testing a breakaway switch or you may destroy the Brake Control.
• The Brake Control employs an inertial sensor. It senses deceleration and generates an output that is based on deceleration, thus the term "Proportional Braking".
• The Brake Control will "HOLD" your trailer with 25% of power setting while you are at a standstill with brake pedal applied for longer than 5 seconds.
• The Brake Control will brake proportionally in reverse. It will apply the appropriate brake voltage based on deceleration.
• For Technical Assistance and Warranty Information call: 1-888-785-5832 or www.tekonsha.com.
• 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.

Installation Guide

WARNING: The Brake Control must be mounted from -90 degrees to +90 degrees nose up. Failure to install within these constraints may cause impaired performance.

Diagram Description: An illustration showing the acceptable mounting angle range for the brake control, from -90 degrees to +90 degrees relative to horizontal.

Wiring Brake Control

Your Brake Control has a new and unique connector located at the back of the control. This connector allows two options to wire your Brake Control:

1. Option 1: Use Pigtail Wiring Harness included. This harness can be installed by following the Generic Wiring Guide.
2. Option 2: Use an OEM specific wiring harness. If your vehicle came with a factory tow package that included a 7-way connector, you can purchase a Tekonsha OEM wiring harness with the Brake Control connector on one end and your specific vehicle's connector on the other.

Display Readings after Wiring the Brake Control

After successfully wiring your Brake Control, you should see the following on the two-digit display:

• Power to Brake Control without trailer connected. (Flashes for 15 seconds then changes to Boost feature engaged/not engaged).
• Power to Brake Control with trailer connected.
• Manual Knob Activated without trailer.
• Manual knob activated (with trailer): '5.4' denotes a hypothetical power output, set using the power knob (Range 0.0 to 13 volts). This indicates voltage output to electric brakes.
• Power to Brake Control but display is in power saving mode (no motion or activity for at least fifteen minutes).
• (Blank Display)

Diagram Description: Visual indicators for "Boost feature engaged" and "Boost feature not engaged" are shown, along with a blank display indicator.

Mounting the Brake Control

Traditional Bracket Mount

• A. Mounting Bracket
• B. #6 x 3/8” Screws
• C. Brake Control Mounting Holes

CAUTION: Drilling or use of longer screws may damage the unit or your vehicle.

1. Securely mount bracket to a solid surface.
2. Insert supplied #6 x 3/8” screws on each side into the mounting holes.
3. Adjust Brake Control to desired position and tighten screws until snug, obtaining the proper mounting angle.

Dash Mounting Clip

• A. Mounting Clip
• B. #6 x 3/8” Screw
• C. Brake Control Attachment Locations

CAUTION: Drilling or use of longer screws may damage your vehicle.

1. Securely mount dash clip to a solid surface.

Attaching Brake Control To Dash Mounting Clip

WARNING: Failure to properly secure the Brake Control into the dash mounting clip may result in loss of or improper operation of the Brake Control.

1. After securely mounting the dash clip to a solid surface, the Brake Control can be attached.
2. Connect wiring harness connector to the Brake Control.
3. Slide the Brake Control into the dash clip so that the rear slots engage with the rear tabs of the clip.
4. Spread apart the front legs of the dash clip and raise the front of the Brake Control to engage with the clip.
5. WARNING: The dash clip allows for three mounting adjustments on each side. The Brake Control must be mounted correctly. Final mounting position should be in the same adjustment slot on each side (see figure 1).
6. Adjust Brake Control to desired position, obtaining the proper mounting angle.

Diagram Description: Figure 1 illustrates the correct and incorrect methods of attaching the brake control to the dash mounting clip, highlighting the engagement of rear slots/tabs and front legs. It also shows the correct orientation (horizontal front, parallel to travel) and incorrect orientations.

Automatic Leveling of the Sensor

The Brake Control will automatically acquire the proper level setting. It will also automatically adjust as you travel up or down hills.

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

1. Connect trailer to tow vehicle.
2. With engine running, hold manual control full left and set Power Knob to indicate approximately 6.0.
3. Drive tow vehicle and trailer on a dry level paved surface at 25 mph and fully apply manual knob.
4. If trailer brakes lock up: Turn power down using power knob.
5. If braking was not sufficient: Turn power up using power knob.
6. Repeat Step (3) until power has been set to a point just below wheel lock up or at a sufficient force to achieve maximum braking power.
7. Using the brake pedal, make a few low speed stops to check the power setting. Trailer braking is initiated and terminated via the stoplight switch. When the brake pedal is released, trailer braking will cease.

Boost Setting

The boost button allows for a more aggressive setting for your trailer brakes and is available in three levels: [ b.I ], [ b.2 ], [ b.3 ]. Each incremental boost setting 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 continued pressing.

Five seconds after setting the boost level, the display will show "Boost On" (indicated by the rightmost decimal). For example:

• With boost off [ .c ]: Power starts at zero and increases with deceleration.
• With boost on level 1 [ b.I ]: Power starts at approximately 13% and increases with deceleration.
• With boost on level 2 [ b.2 ] or level 3 [ b.3 ]: Power starts at approximately 25% and increases with deceleration.

Cases for using the boost button:

• You want trailer braking to 'LEAD' the tow vehicle's braking.
• Towing a full vs. empty trailer.
• Degraded brake performance (most electric brakes require manual adjustment - see Appendix A or a dealer).

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

Typical Boost Settings For Optimal Performance

(with properly adjusted trailer brakes*)

WARNING: Do not exceed Gross Combined Weight Rating (GCWR).

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

NOTES:

• Always warm trailer brakes before setting power. Warm brakes are more responsive. To warm, drive 1/4 mile at 45 MPH with manual lever engaged enough to cause low-level trailer braking.
• WARNING: Power should never be set high enough to cause trailer brakes to lock up. Skidding trailer wheels can cause loss of directional stability.
• Power may need adjustment for different load weights and road conditions.
• Not all trailer brakes will lock up; inability to lock up generally indicates a need for inspection.
• When power is set correctly, you should feel unified braking between trailer and tow vehicle.
• WARNING: Boost setting will be cleared under abnormally low battery conditions. Check boost setting after starting vehicle.

Reverse

When backing a trailer, you can cancel "BOOST" and "HOLD" for three minutes by pressing the boost button continuously for five seconds with the brake pedal depressed. The display will indicate [Blank Display] or [Blank Display].

(If "boost" was active, the right-hand decimal point will also be on.) After three minutes, "BOOST" and "HOLD" features will automatically return to previous settings.

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

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 manufacturer's 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.
4. Note: With drop spindle axles, a modified adjusting tool with about an 80 degree angle should be used.
5. Then rotate the starwheel in the opposite direction until the wheel turns freely with a slight lining drag.
6. Replace the adjusting hole cover and lower the wheel to the ground.
7. 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 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.