FOR TRAILERS WITH 2 OR 4 ELECTRIC BRAKES AND VEHICLES WITH 12 VOLT NEGATIVE GROUND SYSTEMS ONLY.

INSTALLER AND OWNER: Read and follow these installation and adjustment instructions carefully. Leave in tow vehicle for future reference.

This package includes: SYNCRONIZER Controller, Mounting Bracket, Mounting Hardware and Warranty Card.

CONTROLLER MOUNTING

The controller can be mounted in any position using the reversible slotted mounting bracket.

1) Install the mounting bracket to a solid metal surface under the dash using the two screws provided and tighten until snug.

2) Insert screws through the desired mounting bracket holes and into the desired controller anchor holes and tighten until snug.

CONTROLLER WIRING

Read the wiring instructions completely before you begin wiring the controller.

WARNING: All four controller wires must be connected properly for the controller to operate correctly. Failure to do so can cause loss of trailer braking. The controller MUST be installed on 12 volt negative ground systems only. Reverse polarity, I.e. Reversing black battery (+) wire and white ground wire, breakaway kit activation without unplugging tow vehicle/trailer connector or improper wiring will destroy the controller and void the manufacturer's warranty. Hayes Lemmerz recommends that all connections be made using insulated, solder less, crimp style connectors. Use 14 gauge or heavier wiring for all wiring connections.

WHITE GROUND WIRE must be connected to a grounded metal part of the fire wall or directly to the negative (-) terminal of the battery.

WARNING: If not properly grounded, the controller and/or indicator light will not operate correctly which will result in erratic or no trailer brakes and no indicator light.

BLUE BRAKE WIRE must be connected directly to the trailer brake wire.

RED STOPLIGHT WIRE must be connected to the non-powered wire of the stoplight switch or tow package harness.

WARNING: 1989-91 Ford Bronco, Econoline, F-Superduty and F150-350 Series: The red stoplight wire MUST splice into the turn signal connector harness and not the stoplight switch.

BLACK POWER WIRE must be connected through a 20 amp self resetting circuit breaker to the positive (+) terminal of the battery. Route the black wire through a grommet hole in the fire wall to reduce wire grounding and away from the radio antenna to reduce any possible AM radio interference. Do not connect the black wire to any vehicle power supply lines or fuse panels which could cause circuit overload or damage to tow vehicle wiring and vehicle electronics.

AUTOMATIC OPERATION

The automatic mode modulates and controls the current from the battery to the trailer brakes. The

longer the brake pedal is depressed, the greater the current delivered to the trailer brakes until the preset brake power adjustment is reached.

POWER WHEEL ADJUSTMENT

The power wheel is located on the front left side of the controller and is used to adjust the maximum amount of power to the trailer brakes for obtaining smooth, synchronized and optimum tow vehicle and trailer brake response. To increase the maximum amount of power required, rotate the power wheel upward toward the top of the case. To decrease the maximum amount of power required, rotate the power wheel downward toward the bottom of the case.

WARNING: Improper adjustment of the controller could result in loss of trailer brakes, aggressive, grabby, pulsating or delayed trailer brakes.

ROAD TEST AND PERFORMANCE ADJUSTMENTS

To adjust the power wheel setting with the trailer connected, find a flat, hard, dry surface and perform several stops at a moderate speed (25 mph or less)., Under normal brake pedal pressure, a firm braking action should occur. If more/less trailer brake power is needed, according to the combined braking effort of the tow vehicle and trailer, increase/decrease the power wheel setting until the desired braking effort is achieved.

WARNING: Power wheel adjustments may he required based upon speed, trailer load and road conditions. Optimum trailer braking occurs just before the trailer wheels lockup. Trailer brake lockup could cause loss of control of the trailer and/or tow vehicle.

MANUAL OPERATION

The manual slide lever located on the front right side of the controller is used to apply the trailer brakes independently of the tow vehicle or to override the automatic trailer brakes. The further the manual slide lever is moved from the right to the left, the greater the amount of trailer braking effort is applied. The manual lever operation is an independent circuit and overrides the power wheel adjustment to allow full braking effort when required. The indicator light will illuminate from dim to bright as the manual lever is applied and remains off when the manual lever is released. The tow vehicle and trailer brake stoplights will be illuminated during the manual lever activation.

WARNING: The manual operation may not disengage the Cruise Control on some vehicles.

TROUBLE SHOOTING

To verify the brake controller is properly wired, move the manual lever from right to left. The controller indicator LED light, trailer stoplights and trailer brake must function. If the indicator light does not function, the black or white wire connections mav be faulty. If the trailer stoplights and automatic mode do not function, the red wire connection may be faultv. If the trailer brakes do not function, the blue wire connection or the trailer ground may be faulty.

INDICATOR LED LIGHT REPRESENTATION WHILE BRAKES ARE APPLIED AUTOMATICALLY OR MANUALLY.

1) Dim to bright red illumination:

Controller operating normally with power to the trailer brakes.

2) Dim or No red illumination:

White ground wire connection or black battery

(+) wire connection may be faulty or blue wire is shorted to ground.

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