TRIFLEX TRIFLEX BRAKE CONTROL INSTALLATION AND USER GUIDE For use with 12 volt negative ground systems only For trailers with two to eight brakes Read, follow and save this guide for future reference 51140-INS-RB • PAGE 1
This package includes: (1) Brake control module with quick plug (1) Mounting bracket (6) Mounting bracket screws (1) Quick reference card One or more of the following may be needed to complete installation: • Brake control connection harness, supplied with the tow vehicle (if equipped) • CURT quick plug adapter harness - custom connector for specific vehicles.
WARNING: The brake control unit's positive (with 30 amp circuit breaker) and ground wires must be connected directly to the tow vehicle's battery using 10 gauge minimum stranded wire. Connecting to existing wiring or an alternate ground may damage vehicle circuits, lead to failure of the brake control module, loss of trailer brakes or vehicle fire. NOTICE: Removal of the factory supplied quick plug can void warranty.
Controls and Components 1. Digital display 2. Sensitivity adjustment 3. Output adjustment thumb wheel 4. Manual control lever 5. Quick plug connector 6. Switch for manual control max output, 100% or output setting 7. Switch for manual control stoplight activation 8.
CONTROLS AND DISPLAY Output Control The output control thumbwheel establishes the maximum amount of power available to the trailer brakes when braking. The only exception would be when the manual control is setup for 100% braking, see 'Set Manual Control Output and Brake Light Switches'. As the output control is rotated, a flashing display shows the setting. When turned to the right, more power will be available to the brakes; when turned to the left, less power will be available.
changing road conditions. The sensitivity control setting is shown as through with being the least aggressive and being the most aggressive. The display flashes the setting for a few seconds after adjustment is complete. Manual Control The manual control is located on the front of the brake control unit at the left side and only applies trailer brakes. Manual brake control activation is used during initial setup and in situations where a slow reduction in speed is desirable.
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.
INSTALLATION Set Manual Control Output and Brake Light Switches There are two small switches located at the rear of the unit that can be accessed by removing the rectangular cover. Once accessed, the switch positions can be changed using a small pointed tool. In the illustration above, the switch on the right (#2) controls the level of output available to the trailer brakes when using the manual control. The factory default setting is the 'ON' position with the switch down.
Mounting 1. Determine a suitable mounting location.
2. Hold the mounting bracket in the selected position and mark the hole locations through the bracket. 3. Using a 1/8" diameter bit, drill holes in the marked locations. 4. With a screwdriver or a 1/4" nut driver, secure the bracket in place using (2) self threading screws (provided). Do not over-tighten. 5. Mount the brake control unit in the bracket using (4) screws. Wiring Disconnect the tow vehicle's negative battery terminal from its battery post before beginning the wiring process.
WIRING DIAGRAM Feed two 10 gauge wires, one white and black, from the mounted brake control to the battery area. Using a ring terminal, connect the black wire to the ‘AUX’ side of the 30 amp circuit breaker. Leave the white wire to be connected later. Using a 10/12 gauge butt connector, attach the black wire from the ‘AUX’ side of the 30 amp circuit breaker to the brake control's black wire.
NOTE: Stoplight switch connection on Ford vehicles including, Mercury Mountaineer. Do not connect to the red wire with a green stripe. Connect to the light green wire only. For vehicles other than 1989-1991 Ford E and F Series trucks and vans with anti-lock brakes, use a test probe, determine which wire on the tow vehicle's stoplight switch is only "hot" when the pedal is pressed. Splice the brake control's red wire to this wire using a wire tap.
SETUP Once all electrical connections are complete and the single decimal point is seen, while parked on a level surface, plug the trailer's electrical connector into the tow vehicle's plug. Making the trailer connection initiates the mounting position calibration mode. may be seen on the display followed by either or . If appears, recalibration is needed. To recalibrate, unplug and replug the trailer's electrical connector. While calibrating, the display will show or may flash the Output setting.
Start with the output adjustment. Drive forward on a paved or concrete surface that is dry and level. At approximately 25 mph, apply the tow vehicle brakes. If trailer braking is insufficient, adjust the output control to the right. If the trailer brakes lockup adjust the output control to the left. Repeat this step until stops are firm, just short of lockup. Once the output is set, adjust sensitivity. Drive forward to approximately 25 mph and press the brake pedal.
BENCH TEST INSTRUCTIONS Parts Needed: Standard 1156 automotive bulb in a socket, Charged 12V battery, Alligator clip test leads OR wire and wire nuts, 51515 / 51516 Quick plug with pigtails OR push pins NOTE: If a quick plug pigtail is not available push pins can be used to make a direct connection to the female terminals of the TriFlex quick plug housing.
The TriFlex will display that it's checking calibration , that it's calibrating , or that it needs recalibration . If the indication appears, disconnect and reconnect the bulb from the blue wire to recalibrate. It will show when disconnected, and / or during calibration, followed by two decimal points when complete.
BENCH TEST DIAGRAM IMPORTANT: Read and follow all warnings and cautions shown on the battery PAGE 17
TROUBLE SHOOTING GUIDE - TEST WITHOUT TRAILER FIRST No Trailer Connected Condition Display Decimal point does not Blank light when brake pedal or manual control is used Decimal point on after 30 min of inactivity Decimal Display shows L.b Can also happen with trailer connected Display shows E.1.
With Trailer Connected Condition Probable Cause Probable Solution Display shows only one Decimal decimal point when power is applied to control.
NOTES PAGE 20
