SERVICE MANUAL 440-1015 FOR
Contents
1. or maintenance specified in any Cargo Towing Solutions sales literature specific action sheet service manual or other applicable literature or e products altered or utilized in a manner not approved by Cargo Towing Solutions or subjected to abuse misuse improper maintenance negligence or accident THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE ACCEPTED BY BUYER IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE Buyer s sole remedy the event of a breach of the foregoing warranties is the repair or replacement of the affected product by Cargo Towing Solutions as determined by it in its sole discretion NO merchan dise will be accepted for warranty credit consideration without a Returned Goods Authorization Number issued by the Customer Service Representative 812 655 4544 If upon inspection by the Returned Goods Technician the merchandise is found to be free from defects in material and workmanship then the warranty claim shall be deemed invalid and the merchandise shall be held for a period of 15 days pending disposition by the buyer and an inspection charge may be applied by Cargo Towing Solutions BUYER AGREES THAT IN NO EVENT WILL CARGO TOWING SOLUTIONS LIABILITY FOR ALL LOSSES FROM ANY CAUSE WHETHER BASED ON CONTRACT NEGLIGENCE STRICT LIABILITY OTHER TORT OR OTHERWISE EXCEED BUYER S NET PURCHASE P2. sure brakes are working If not check for loose or broken connections Controller beeps three times repeatedly e Short Circuit Check for bare wire or loose connections in ground Also check for power wires making contact with each other or grounded surface Controller beeps four times repeatedly e Overload Check for too many running lights or too many axles more than three heavy duty Controller beeps five times repeatedly Turn Lights On e Make sure that the trailer running lights are on e sure the in cab controller is plugged into the cigarette lighter receptacle an accessory power receptacle e Check for bad connections in plugs the trailer and towing vehicle e Make sure plug pins are tight and not worn from use or dragging on the ground e sure there is no corrosion Check ground connections Make sure trailer is grounded to towing vehicle and trailer battery Brakes are not aggressive enough all green lights are illuminated e sure brake system is bled properly see Section Installation Check Procedures Bleeding the Brakes e If drum brakes adjust brakes e Loosen or remove attaching bolts Remount the unit with the rear end of the Hydrastar XL elevated approximately 2 inches Unit is not putting out pressure e sure brake system is bled properly See Section Installation Check Procedures Bleeding the Brakes e With no power to the unit remov
3. to supplement the tow vehicle brake system At no time should the towed vehicle brake system be relied upon to stop the towing vehicle WARNING All of the electrical power required to operate the trailer brakes is drawn from the trailer mounted brake battery It is critical that the trailer brake battery is deep cycle_battery and has a minimum capacity of 17 amp hours Operation with a weak or discharged battery can cause the actuator to malfunction resulting in possibly serious or fatal injuries and or property damage DO NOT ATTEMPT TO OPERATE THE UNIT IF ALOW VOLTAGE CONDITION IS SIGNALED WARNING The CARGO TOWING Hydraulic brake actuator is not intended to function as a park brake When stopped for extended periods of time apply the towing vehicle park brake and release the brake pedal WARNING Failure to properly install protect operate and maintain the actuator system can cause a malfunction resulting in possibly serious or fatal injuries and or property damage WARNING The tow vehicle trailer tail amp running lights MUST BE TURNED ON BEFORE PERFORMING ANY TOWING for the actuator to operate correctly and for the breakaway battery to be recharged Failure to turn the lights ON can cause the actuator to malfunction or the breakaway battery to become discharged resulting in possibly serious or fatal injuries and or property damage WARNING Should any SYSTEM PROBLEM STATUS CODE signals occur immediately sto
4. 1015F Page 3 of 14 In Cab Controller operation is as follows GAIN SETTING Press either the UP arrow to increase the amount of trailer braking or the down arrow to decrease the amount of trailer braking The selected gain level will be shown by the number of green illuminated LED s the face of the unit One light corresponds to the lowest setting six lights corresponds to the highest gain setting STOP BUTTON Press the red square STOP button to manually apply the trailer brakes Depending on the gain setting selected 1 to 6 red LED s will illuminate to indicate the level of braking being generated The brake lights on the trailer also automatically turn on whenever the manual brake button is depressed SYSTEM STATUS CODES Yellow status LED flashes audible alarm beeps Of Beeps or Flashes Error Indication 1 Low Battery Voltage trailer brake battery 2 Open Circuit Internal Components motor solenoid 3 Short Circuit Internal Components motor solenoid 4 Overload actuator unit overheated RAPID Loss of Power tail running lights not turned ON or faulty connection to trailer D IMPORTANT SAFETY MESSAGES WARNING Thoroughly read and understand this manual before installation Failure to properly follow this manual could cause a malfunction resulting in possibly serious or fatal injuries and or property damage WARNING The brake system on the towed vehicle is intended only
5. 2 VOLTS FOR LIGHTS THE CIGRETTE LIGHTER RECEPTACLE MUST ALSO ji BE WIRED FOR 12 VOLTS IN CAB CONTROLLER WIRED FOR 12 VOLTS DC CIGARETTE LIGHTER RECEPTACLE 12 VDC REQ TOW VEHICLE WaW LIGHTS LH TURN SHGNAL BULB RH TURN SIGMAL NEGATIVE GROUND WHITE CONNECT TO TOW VEHICLE RUNNING LIGHT 12 VOLT FUSE BLOCK SIGNAL COUPLER SUPPLIED IN TOWING VEHICLE BY CARGO TOWING SOLUTIONS TRAILER BRAKES 3 xL 31 PD arte BROWN VOLTAGE CONVERTER f TAIL LIGHTS LA TURN SiGhMAL TELLOW RH TURN SIGNAL GREER BREARAWAY SVATCH NEGATIVE GROUND WHITE CUSTOMER SUPPLIED BRARES NOTE USE CARGO TOWING SOLUTIONS SIGNAL COUPLER FOR 24V SYSTEMS OR 12V SYSTEMS WHEN CONTROLLER WILL NOT COMMUNICATE WITH THE TOW VEHICLE ATTACH THE SIGNAL COUPLER TO THE POSITIVE WIRE ON THE 12V RECEPTACLE IN THE TOW VEHICLE AND RUN THE OTHER END OF THE WIRE TO THE FUSE BLOCK FOR THE 12V RUNNING LIGHTS ON THE VEHICLE ECN 05157 Manual 440 1015F Page 8 of 14 WIRING SCHEMATIC FOR TOW VEHICLES WITH AIR BRAKES OR VEHICLES HAVING NO DIRECTIONAL SIGNALS WIRING INSTRUCTIONS FOR TOWING VEHICLES WITH AIR BRAKES OR SEPARATE AMBER TURN SIGNAL LIGHTS OR NO TURN SIGNAL LIGHTS Splice the brake light wires or brake switch wire from the tow vehicle to the yellow and green wires coming from the Ele
6. D WHITE NEGATIVE GROUND WHITE 1 BRAKE BATTERY BRAKES 3 NOTE DISCONNECT ANY BRAKE CONTROLLER INSTALLED IN THE TOW VEHICLE IT IS BEST TO USE A CONVERTER PIG TAIL WHICH WILL KEEP ANY BRAKE CONTROLLER SIGNAL FROM INTERFACING WITH THE XL SYSTEM I E A SEVEN RV PLUG CONVERTED TO A 4 WIRE FLAT SYSTEM ECN 05157 Manual 440 1015F Page 6 of 14 NOTE DISCONNECT ANY BRAKE CONTROLLER INSTALLED IN THE TOW VEHICLE OR CONVERT TO A FOUR WIRE FLAT PLUG F Installation Check Procedures Checks With Tow Vehicle Engine NOT RUNNING Park Brake SET In Cab Controller Unplugged 1 Turn on the tow vehicle running light switch SEE FOLLOWING NOTE Verify that the trailer running lights are ON and that power is being supplied to the BROWN wire on the CTS actuator Make any necessary repairs Apply and release the tow vehicle brake pedal several times Each time the pedal is pressed the brake lights on both the tow vehicle and trailer should be illuminated and power should be supplied to both the yellow and green wires on the actuator Make any necessary repairs Turn OFF the tow vehicle tail running light switch Activate the breakaway system by pulling out the breakaway switch plunger Verify that power is being supplied to the blue wire on the actuator and that the trailer brakes are functioning correctly Replace the plunger on the emergency breakaway switch NOTE For Trailers with multiple tail ru
7. RICE NOR WILL CARLISLE CARGO TOWING SOLUTIONS BE LIABLE FOR ANY SPECIAL INCIDENTAL CONSEQUENTIAL OR EXEMPLARY DAMAGES The foregoing warranties will continue in effect so long as the product is serviced and maintained in ac cordance with Cargo Towing Solutions instructions and with genuine Cargo Towing Solutions manufac tured replacement parts These warranties may not be altered or amended except by a written instrument signed by buyer and a duly authorized officer of Cargo Towing Solutions Any claim not made in compli ance with this limited warranty shall conclusively be deemed waived ECN 05157 Manual 440 1015F Page 14 of 14
8. SERVICE MANUAL 440 1015 FOR Towing Solutions Worldwide HYDRAULIC BRAKE ACTUATOR KIT DOT 3 DOT 4 BRAKE FLUID This Document is Applicable to DESCRIPTION BATTERY PACK IN CAB CONTROLLER KIT ACTUATOR KIT 1000 PSI ACTUATOR KIT 1200 PSI ACTUATOR KIT 1600 PSI IMPORTANT This actuator will not function correctly with any other brand or type of brake controller IC A R G Of Towing Solutions Worldwide 11404 Bond Road Harrison Ohio 45030 812 655 4544 Fax 513 202 0079 Website www cargobrake com Email cargobrake yahoo com ECN 05157 Manual 440 1015F Page 1 of 14 MANUAL 440 1015 TABLE OF CONTENTS SECTION DESCRIPTION PAGE A Features 2 B Compatability 2 C System Components 2 3 D Important Safety Messages 4 Installation Instructions 5 Actuator Wiring 6 F Installation Check Procedures 7 G Signal Controller Kit 10 H DOT Inspection Note 11 Mounting Dimensions Replacement Parts List 12 J Trouble Shooting Guide 13 Limited Warranty 14 A Features The CARGO BRAKE trailer brake actuator is a microprocessor based 12 Volt DC system if using a 24 Volt DC system see Section F Actuator Wiring 24 Volt Electrical Wiring Diagram for use on single two and three axle trailers equipped with hydraulic brakes This unit requires a 17 amp hour trailer brake deep cycle battery and an emergency breakaway switch CARGO BRAKE recommends a CARGO BRAKE Battery Pack ki
9. ailer brake actuator Trailer Actuator Wires BROWN WIRE Connect the brown wire from the actuator to the tail light running light circuit on the trailer YELLOW WIRE Connect the yellow wire from the actuator to the left turn signal brake light circuit on the trailer GREEN WIRE Connect the green wire from the actuator to the right turn signal brake light circuit on the trailer WHITE WIRE Connect the white wire from the actuator to the negative terminal on the trailer battery and to both a ground connection on the trailer and to the ground wire in the wiring harness from the tow vehicle The unit will not operate properly without a direct connection to the ground circuit on the towing vehicle Grounding between the trailer ball and coupler without a direct connection to the towing vehicle ground circuit will result in system errors BLACK WIRE Connect the black wire from the actuator to the positive terminal on the trailer battery and to one side of the emergency breakaway switch BLUE WIRE Connect the blue wire from the actuator only to the remaining unused emergency break away switch terminal IT MUST NOT BE CONNECTED TO ANY OTHER CIRCUIT 12 Volt Electrical Wiring Diagram BRAKES TOW VEHICLE TRAILER TAIL LIGHTS BROWN TAIL LIGHTS BROWN LH TURN SIGNAL YELLOW LH TURN SIGNAL YELLOW RH TURN SIGNAL GREEN RH TURN SIGNAL GREEN BREAKAWAY SWITCH NEGATIVE GROUN
10. ators manufactured and sold by Cargo Towing Solutions are warranted to be free from defects in material and workmanship when properly installed used and maintained under normal and proper use for a period of 2 two years from date of delivery to the original purchaser vehicle in service date subse quent to installation of Cargo Towing Solutions brake actuator products or 2 two years from purchase date of a free standing unit No claim for breach of warranty will be allowed unless the party making the claim is the original purchaser of the brake actuator the Buyer promptly notified Cargo Towing Solutions during the warranty period of the claimed material or workmanship defect is found within the warranty period properly documented by buyer and CARGO TOWING SOLUTIONS is notified in writing within 30 days from failure and provides Cargo Towing Solutions with the Serial Number and any substantiation which may include but is not limited to the return of the Product and any other information which Cargo Towing Solutions may reasonably request This warranty shall not apply to any damage or lost cause by any or all of the following circumstances or conditions e Damage caused during installation e Parts accessories materials or components which have not been approved by Cargo Towing Solutions e Misapplication misuse or failure to following the directions or observe the cautions and warnings on installation operation application inspection
11. button on the in cab controller 6 Observe the tube end in the container for air bubbles escaping and continue until no more bubbles are emitted into the container 7 Tighten the bleed fitting securely Release the red button on the in cab controller and remove the plastic tubing CAUTION During bleeding periodically check and replace the fluid in the reservoir Running the unit without adequate brake fluid will cause permanent damage Repeat Steps 3 through 6 for each brake on the trailer Checks with Tow Vehicle Engine Running USE EXTREME CAUTION 1 Select the maximum gain setting 6 Green LED using the in cab controller Apply and HOLD the red button on the in cab controller release the park brake start the engine and place the transmission shift lever in Forward With the engine at low idle speed release the brake pedal enough to allow the tow vehicle to move slowly forward Apply a small force to the brake pedal The trailer brakes should be felt to apply noticeably slowing the tow vehicle Repeat this procedure 2 3 more times 2 Lower the gain setting to number 5 and perform Check Procedure 8 several more times trying various levels of applied pedal force 3 Continue checking at various gain setting steps until you are thoroughly experienced at operating the system and have established the appropriate gain setting for the particular trailer involved H DOT inspection Note To demonstrate that the actuator and trailer b
12. ctraStar HydraStar XL It will be necessary to splice the directional light wires from the tow vehicle to the trailer directional lilghts TOW VEHICLE TRAILER RUNNING LIGHTS CIRCUITS RUNNING LIGHTS BROWN BRAKE LIGHT SWITCH LH TURN SIGNAL YELLOW SWITCH RH TURN SIGHAL GREEN BREARKAWAY NEGATIVE GROUND WHITE I BRAKE I BATTERY NEGATIVE GROUND WHITE RIGHT TURN SIGNAL LIGHT i NOTE DISCONNECT ANY BRAKE CONTROLLER INSTALLED IN THE TOW VEHICLE BRAKES Dar LEFT TURN SIGNAL LIGHT ECN 05157 Manual 440 1015F Page 9 of 14 Towing Solutions Worldwide E The controller signal coupler kit is used when the controller cannot communicate with the CTS systems brake actuator To determine if the harness is required connect the unit according to the instructions in the owner s manual If the controller constantly beeps with the towing vehicle lights turned on the vehicles electrical system may be filtering and weakening the RF signal in the controller If this occurs install the signal coupler supplied with the unit according to the instruction sheet If there is a rental situation where there are numerous towing vehicles involved the umbilical cord may be a better solution Obtain an umbilical cord harness from CTS PART NUMBER 304 7160 Step 1 Run the wire direct
13. detected by the internal monitoring system The in cab controller is equipped with colored LEDs to indicate gain setting green brake output red and system problem status codes yellow It also has pushbutton switches to adjust the output of the trailer brakes versus the towing vehicle i e gain and to manually apply the trailer brakes The in cab controller is easily installed by inserting its power plug into the cigarette lighter receptacle not an accessory power receptacle on the tow vehicle and turning the running lights on Note that the unit must be plugged in each time that the towing vehicle is started The unit will automatically check to make sure that the running lights are on and that the system is functioning as designed In the event that a problem is detected the unit will flash the yellow status light on the face of the unit and will make a series of audible beeps The number of beeps is an indication of the problem that the system has detected Count the number of beeps and check the chart on the back of the unit to obtain direction on possible causes of the problem see Section J Trouble Shooting Guide The unit must be unplugged each time the tow vehicle is taken out of service and the running lights are shut off A series of rapid beeps from the unit is an indication that you either are driving without having your running lights on or that you forgot to unplug the unit when the vehicle was shut off ECN 05157 Manual 440
14. e the filler cap Place a finger the reservoir A screened tube fixed place should be felt If this tube is not felt or it moves around the unit needs repaired e Remove the attaching bolts Have a second person depress the brake pedal on the towing vehicle and hold it down Have a second person slowly lift the rear end of the Hydrastar XL unit The pitch of the motor should change as the unit is lifted higher and higher If this does not occur the unit need repaired Brakes do not apply when pressing on the brake pedal and vehicle and trailer are not moving e When the vehicle and trailer are not moving the brakes will not activate when you press on the brake pedal Raise the gain setting until all six green lights are illuminated Apply and HOLD the red button on the in cab controller All red lights will come on for an instant and then drop to one to three red lights Trailer jerks when brakes are first applied e Turn gain setting down so fewer green lights are illuminated e If the trailer has drum brakes back off of the brake adjustment slightly on all trailer wheels Trailer lights flicker e Battery charger in the Hydrastar XL is cycling and off This may be eliminated by running a brown wire directly from the trailer plug to the brown wire on the Hydrastar XL unit ECN 05157 Manual 440 1015F Page 13 of 14 Towing Solutions Worldwide K LIMITED WARRANTY and LIMITATION OF LIABILITY Brake Actu
15. from the socket to the 12 V DC fuse block of the towing vehicle See Wiring Diagram Step 2 Ground the socket to the towing vehicle Step 3 Test the controller to see if the settings can be changed If the controller beeps constantly with the lights on Use the umbilical cord option See Figure 1 WIRE TO WIRE 1 on 12 V DC SOCKET WIRE DIRECT TO 12 V DC FUSE BLOCK OF TOWING VEHICLE FIGURE 1 Signal Coupler NOTE Use either wire end of Signal Coupler VEHICLE 12 V DC SOCKET GROUND ANYWHERE ON TOWING VEHICLE SIGNAL COUPLER WIRE DIRECT TO 12 V DC FUSE BLOCK OF TOWING VEHICLE 11404 Bond Rd Harrison OH 45030 Call 812 655 4544 www cargobrake com Copyright 2014 CTS WORLDWIDE All Rights Reserved ECN 05157 Manual 440 1015F Page 10 of 14 Bleeding the Brakes 1 Obtain needed materials Plastic tubing inside diameter to fit bleed fitting snugly Clear clean container Brake Fluid DOT 3 or DOT 4 from new container 2 Block the wheels of the trailer and tow vehicle 3 Starting at the rearmost trailer axle open the bleed fitting one half 1 2 turn on the brake farthest from the actuator unit 4 Attach one end of the plastic tubing onto the bleed fitting and immerse the other end in a clear container partially filled with brake fluid 5 Turn on the tow vehicle tail running light switch select the maximum gain setting then activate the actuator unit by applying and holding the red
16. g lights it may be necessary to install a powered tail light converter to insure that adequate power is available to operate the trailer brake actuator If a converter is not available tie the yellow and green wires from the XL to the brake light wire of the towing vehicle C System Components Trailer Mounted Actuator The CARGO BRAKE system is an electric hydraulic brake actuator which includes a microprocessor and an accelerometer The accelerometer is used to sense the amount of braking being generated by the towing vehicle Based on that input the microprocessor then automatically adjusts the output of the unit to generate a comparable amount of trailer braking Unlike a traditional electronic brake control the electrical power required to actuate the trailer brakes is drawn entirely from the trailer mounted brake battery deep cycle 1 7 amp hour minimum capacity To insure that the trailer brake battery remains fully charged at all times a 3 amp battery charger is included as an integral part of the trailer mounted actuator Power for that battery charger is drawn ECN 05157 Manual 440 1015F Page 2 of 14 from the running light circuit on the tow vehicle Thus it is critical that the tow vehicle running lights are on whenever the trailer is being towed Note that it is also critical that the trailer brake battery is not connected to any other charging circuit on the tow vehicle Connecting the trailer brake battery to a second charg
17. ing source will cause sporadic operation and communication errors between the actuator and in cab controller Trailer Mounted Brake Battery All of the power for the trailer brake actuator is drawn from the trailer mounted trailer brake battery For proper operation the system needs deep cycle battery with a minimum capacity of 17 amp hours Note that the trailer brake battery also provides power to the actuator in the event of an emergency breakaway Break Away Switch The system requires an emergency breakaway switch The breakaway switch is mounted on the trailer and is connected electrically to the trailer brake battery and to the CARGO BRAKE actuator The switch is also connected mechanically to the tow vehicle When a breakaway condition occurs the plunger on the breakaway switch is pulled out by the tow vehicle thereby completing an electrical circuit between the trailer brake battery and the breakaway circuit on the CARGO BRAKE actuator When the CARGO BRAKE actuator senses a breakaway condition the trailer brakes are automatically applied at full power In Cab Controller STATUS CODES RATE GAIN STATUS 1 LOW BATTERY 2 OPEN CIRCUIT 3 SHORT CIRCUIT 4 OVERLOAD RAPID TURN LIGHTS ON T 0 0 0 MUST OPERATE WITH RUNNING LIGHTS ON The in cab controller gives the vehicle operator a means to increase or decrease the amount of trailer braking It also provides both audible and visible indications of any problem
18. nning lights the tow vehicle may require a Power Taillight Converter to avoid blown fuses Vehicles with separate brake and turn signal amber Lights will also require a converter In Cab Controller Operation 1 2 4 With the tail running light switch OFF plug the in cab controller cord into the cigarette lighter receptacle not an accessory power receptacle A beeping sound should be heard and the in cab controller should display a rapidly flashing yellow light Turn on the light switch ithe sound and flashing light should stop If it continues to sound and flash recheck for 12 volts to the BROWN wire and or for correct GROUND circuit wiring Repeatedly press the UP or DOWN arrow switches on the controller From 1 to 6 green LED indicators should glow to indicate that various gain settings are being selected Select maximum gain setting 6 green LED press and hold the square red STOP switch From 3 to 6 red LED indicators on the in cab controller should glow and the trailer brake lights should be illuminated Apply and release the tow vehicle brake pedal several times Each time the pedal is pressed from 1 to 3 red LED indicators should glow and the trailer brake lights should illuminate ECN 05157 Manual 440 1015F Page 7 of 14 FOR UNITS WHICH CANNOT COMMUNICATE WITH THE ACTUATOR IN SOME TOW VEHICLES OR VEHICLES WITH 24 VOLT ELECTRICAL SYSTEMS NOTE THE TRAILER MUST BE WIRED FOR 1
19. p the tow vehicle trailer and make all necessary repairs see Section J Trouble Shooting Guide Failure to properly maintain the actuator system can result in possibly serious or fatal injuries and or property damage ECN 05157 Manual 440 1015F Page 4 of 14 D Actuator Before Starting 1 Installation Instructions Trailer The following materials are required to properly install the Hydrastar XL unit e f your trailer is not already equipped with brake lines you will need enough 3 16 inch diameter automotive brake line to connect the trailer brakes to the Hydrastar XL unit Note that inch diameter brake line is recommended for 3 axle trailers or for trailers where the total brake line length exceeds 25 feet Where possible steel tubing is preferred e 4 pieces of 10 mounting hardware to mount the Hydrastar XL unit to the trailer e 1 quart of DOT 3 or DOT 4 brake fluid from a new sealed container e 1 emergency breakaway kit The emergency breakaway kit must include 12 VDC 17 A H deep cycle battery minimum e Wire See Section Actuator Wiring for proper wire size Flush existing brake system and lines with mineral spirits not mineral oil DOT 3 or DOT 4 brake fluid prior to connecting the Hydrastar XL unit Examine all trailer brakes and associated brake lines and fittings to assure they are in good condition Repair any leaks and replace worn or damaged brake lines shoes or pads Ins
20. pect the trailer brakes to be sure they are properly adjusted Consult your trailer owner s manual for instructions on how to adjust the trailer brakes The Hydrastar XL unit contains sensitive electronics that must be protected Drilling additional holes in the housing or electrostatically painting the Hydrastar XL unit or welding anywhere on the Hydrastar XL unit will damage the unit making it inoperable and will void the manufacturer s warranty Always remove the Hydrastar XL from the trailer before doing any welding repair or modifications to the trailer structure Mounting the Trailer Brake Actuator Trailer Brake Battery and Emergency Breakaway Switch 1 Position the trailer as if it were connected to the towing vehicle The actuator must be installed at a location on the trailer that is level to insure proper operation Failure to properly level the unit may result in sporadic operation Select a mounting area for the actuator on the trailer that will provide easy access to the trailer brake battery the emergency breakaway switch and the trailer tow vehicle electrical connector The mounting location should give consideration to protecting the unit from road debris and from unnecessary abuse l e The unit should not be used as a step The long side of the actuator must be mounted parallel to the trailer centerline so that the wiring is directed to the front of the trailer Failure to properly align the unit may result in s
21. poradic operation The actuator must be mounted in a horizontal position with the filler cap up MUST BE PARALLEL TRAILER o ACTUATOR g Attach the actuator to the trailer by installing four 4 10 screws through the mounting holes The trailer brake battery can be mounted at any convenient location on the trailer Mount the battery enclosure with 2 0 25 inch diameter screws to trailer giving consideration to the fact that the battery is heavy and requires adequate support Mount the emergency breakaway switch on the tongue of the trailer providing for a direct mechanical link between the switch plunger and the towing vehicle Mount the switch with a 0 25 inch screw Remove the red plastic plug from the brake port on the actuator exposing a 3 16 inch inverted flare fitting Connect the brake line from the trailer to this fitting ECN 05157 Manual 440 1015F Page 5 of 14 9 Fill the actuator reservoir with DOT 3 or DOT 4 brake fluid and replace the cap CAUTION Always refill with new brake fluid from a sealed container Never reuse old or dirty brake fluid Clean off any brake fluid that may have been spilled on the trailer or actuator unit E Actuator Wiring Connect the six wires from the trailer mounted actuator to the trailer wiring system as follows See Diagram NOTE Trailer wiring to the actuator must be 14 gauge or larger wires WARNING Failure to wire the unit properly can result in damage to the tr
22. rake system are functioning properly adjust the up arrow on the cab controller until the system is set at its maximum gain setting 6 green LED s illuminated Press and hold the red STOP button on the in cab controller and attempt to drive through the trailer brakes This will apply the maximum power to the trailer brakes and will demonstrate to DOT personnel that the trailer brakes are functioning properly ECN 05157 Manual 440 1015F Page 11 of 14 Mounting Dimensions Replacement Parts List 16 50 15 70 GASKET MANIFOLD 4 88 LL by il ji 3 38 5 35 4 85 1 AX 213 MOUNTING FILLER CAP 3 oe 14 39 OUTPUT 5 65 lal PORT 1 REPLACEMENT PARTS LIST OUTPUT PORT ADAPTER ASSEMBLY 1 4 INCH INVERTED FLARE KIT __1__ GASKET MANIFOLD SIDE 32 7640 FILLER CAP PARTS KIT REPLACEMENT IN CAB Not Shown 381 7022 CONTROLLER TRAILER BATTERY PACK COMPLETE 12 VDC 17 A H DEEP CYCLE BATTERY ENCLOSURE HARDWARE BREAKAWAY SWITCH INSTRUCTION SHEET AND STRAPS Not Shown 304 7160 SIGNAL COUPLER ECN 05157 Manual 440 1015F Page 12 of 14 J Trouble Shooting Guide Controller beeps one time repeatedly e Low Battery Check for low battery by pulling breakaway pin Voltage should drop from 12 volts DC to 10 11 volts DC If drop is larger charge or replace battery Controller beeps two times repeatedly e Open Circuit Pull breakaway pin Make
23. t number 304 7131 complete with a 12 VDC 17 A H deep cycle battery enclosure hardware and breakaway switch The CARGO BRAKE actuator is unique in that it is totally trailer mounted The actuator connects to the wiring on the trailer and does not require any modifications or additions to the wiring on the tow vehicle Any vehicle that can connect to the trailer and power the trailer s lights can make use of the CARGO BRAKE trailer brake actuator The in cab controller is provided by a pendant that plugs into the cigarette lighter receptacle not an accessory power receptacle on the tow vehicle No modifications to tow vehicle or to the tow vehicle wiring are required to make the in cab controller unit operate correctly Multiple vehicles can share a single in cab controller by simply moving the in cab controller from one vehicle to another Additional in cab controller units are available and are compatible with all CARGO BRAKE trailer brake actuators B Compatibility The CARGO BRAKE trailer brake actuator should function properly so long as the towing vehicle can power the running lights and stop lights on the towed trailer Note that vehicles and trailers that have amber turn signals typically require the use of a tail light converter to insure proper operation The CARGO BRAKE actuator draws approximately 1 3 amps of power from the tail light circuit to power the on board battery charger On trailers with multiple runnin
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