Hayes G2 Installation Manual

SAFETY SYMBOLS
WARNING
Indicates a potentially hazardous situation
Electronic Brake Controller
that, if not avoided, could result in death or
Hayes BRAKE CONTROLLER P/N 81792K
serious personal injury.
INSTALLATION MANUAL
CAUTION
For trailers with 2-8 electric brakes and vehicles
Indicates a potentially hazardous situation
with 12 volt negative ground systems only.
that, if not avoided, could result in damage to
product or property.
TIP:
Special Dual-Mated "Quik-Connect"
TIP
Wiring Harnesses are available for all
Contains helpful information to facilitate
Hayes Brake Controllers fitted with a connector
installation.
on the wire leads, making connection a snap.
Harnesses are available through all dealer CAUTION:
resources.
In the automatic mode, noticeable braking
is applied only when the deceleration
sensor detects deceleration. With the vehicle at rest
and the brake pedal depressed, there should only be
READ AND SAVE THESE INSTRUCTIONS
slight output to the trailer brakes.
» Before beginning installation, read and become
familiar with these instructions.
» Leave in tow vehicle for future reference.
» IMPROPER INSTALLATION AND OPERATION
COULD CAUSE PERSONAL INJURY, AND/OR
EQUIPMENT AND PROPERTY DAMAGE
fig. 1 Front View

Controller Wiring Instructions

Controller Wiring Instructions
Important:
TIP:
Make all controller wiring connections to the wiring
Recommended use with the HBCC
harness before connecting the harness to the
dual-mated harness for best results.
vehicle.
The following chart describes the function of each of the controller's wires:
Order: Color: Function: Wire Size Connect to:
(AWG):
1 White Ground 16 Grounded metal part of firewall or directly to
st
the negative (-) terminal of the battery.
Connect this wire first.
2 nd Black + Connection to the 12 Positive (+) terminal of the battery. MUST have
vehicle's power a self-resetting Circuit Breaker in-line between
system the controller and the battery. See chart for
proper size. Route the black wire through a
grommet hole in the firewall to prevent wire
grounding and away from the radio antenna
to reduce any possible AM radio interference.
Connect this wire second.
3 Red Stoplight 14 Non-powered stoplight wire (of the stoplight
rd
switch) or trailer tow wiring harness. It is
recommended that a 20-amp in-line fuse
be installed between the controller's red wire
and the stoplight switch. The fuse is
required in 1999 & later Fords.
4 Blue Output to trailer brakes 12 The trailer brake wire or tow vehicle/trailer
th
connector.
Mounting Angles
Mounting angles between -35 and + 90 degrees can
be accommodated by the controller. THE UNIT MUST
BE INSTALLED SO THAT IT IS PARALLEL WITH THE
TRAVEL OF THE TOW VEHICLE AND TRAILER.
Universal Quik-Receiver
-35˚ to 90˚
Front of Vehicle
fig. 2 Acceptable Mounting Angles
Controller Mounting and Installation
Attach Universal
Quik-Receiver
to vehicle dash
LCD Display
Setup
Insert G2 into
Adjustment
Universal
Buttons
Quik-Receiver
Manual Override
Slide Lever
fig. 3 Attach Universal Quik-Receiver to Vehicle Dash
Self-Resetting Circuit Breaker Size Chart. NOTE: Each trailer brake magnet is assumed to draw 3 amps of
current and each brake lamp bulb is assumed to draw 2 amps.
Number of Brake Light Bulbs
(tow vehicle Plus trailer)
4 Bulbs (minimum)
5 Bulbs
6 Bulbs
7 Bulbs
8 Bulbs
9 Bulbs
SW
fig. 4 Vehicle Mechanical
Stoplight Switch
Positive
(+)
Use Self-Reseting
Circuit Breaker
See Chart for Size
(not furnished)
(-) Chassis/Ground
Negative
Controller and Universal Quik-Receiver ®

Controller and Bracket Mounting

»
The Universal Quik-Receiver provided is to be used
» The controller must be mounted with the back of the
for mounting the controller to the tow vehicle.
controller toward the front of the vehicle.
» DO NOT MOUNT CONTROLLER UPSIDE DOWN
» Use the reversible slotted mounting bracket.
OR SIDEWAYS.
» Do not mount the controller upside down or sideways.
WARNING:
If the controller is mounted incorrectly, the
WARNING:
three axis accelerometer cannot operate
If the controller is mounted incorrectly, the
correctly and may cause loss of braking.
deceleration sensor arm cannot operate
correctly and may cause loss of braking.

Installation Steps

1. Install the Universal Quik-Receiver to a solid surface
under the tow vehicle dash using the two machine
screws or VHB high bonding tape applied to the
Installation Steps
Universal Quik-Receiver.
See fig. 2 Acceptable Mounting Angles and fig. 3
1. Install the mounting bracket to a solid surface
Attachment of Universal Quik Receiver.
under the tow vehicle dash using the two machine
screws and fasteners provided. Tighten until snug.
2. Mount in a location which allows the driver to easily
See fig. 3 Attachment of Mounting Bracket
apply the manual override and see the digital display.
2. Insert four of the self-tapping screws provided
through the mounting bracket holes and into the
WARNING:
desired controller anchor holes. Tighten until snug.
All four controller wires must be connected
3. Mount in a location which allows the driver to easily
properly for the controller to operate correctly.
apply the manual override and see the Red
Failure to properly connect all four wires can cause Indicator Light.
loss of trailer braking.
Improper wiring will destroy the controller and void
the manufacturer's warranty.
Number of Trailer Brakes
2 Brakes 4 Brakes 6 Brakes 8 Brakes
20 AMP 30 AMP 30 AMP 40 AMP
20 AMP 30 AMP 30 AMP 40 AMP
20 AMP 30 AMP 40 AMP 40 AMP
30 AMP 30 AMP 40 AMP 40 AMP
30 AMP 30 AMP 40 AMP 50 AMP
30 AMP 40 AMP 40 AMP
50 AMP
Non-Powered Stoplight Wire Stoplights
20 Amp In-line Fuse
(not furnished)
20A
Ground
Red
G2
Black
Brake
White
Controller
CB
Blue
Trailer Brakes
Trailer Ground
Tow Vehicle/Trailer
Electrical Connector
CAUTION: WARNING:
WARNING: WARNING:
Care must be taken to ensure that the All four controller wires must be connected Improper connections may result in no
The white wire must be connected to a
mounting surface is rigid enough to properly for the controller to operate trailer brakes or destroy the controller and
known good ground (preferably the
prevent excessive vibration. correctly. void the manufacturer's warranty.
negative battery post).
Excessive vibration may result in poor performance.
Failure to properly connect all four wires can cause
loss of trailer braking.
Improper wiring will destroy the controller and void
Read all wiring instructions prior to making
the manufacturer's warranty.
electrical connections to the tow vehicle.
controller and void the manufacturer's warranty.
WARNING:
CAUTION:
Follow wiring instructions. WARNING:
Care must be taken to ensure that the
WARNING:
mounting surface is rigid enough to Improper connections may result in no
Improper wiring will destroy the controller
To reduce the risk of injury or damage
prevent excessive vibration. trailer brakes or destroy the controller
and void the manufacturer's warranty.
to property:
Excessive vibration may result in poor performance.
» Always connect the white wire first and the
black wire second.
CAUTION:
technical suppo
» All four controller wires must be connected properly
DO NOT connect the black wire to any
latest controller red stoplight wire to stoplight
for the controller to operate correctly.
vehicle power supply line or fuse panel
Read all wiring instructions completely switch connections.
»
Failure to connect the wires correctly can cause that could cause circuit overload or damage to
before you begin wiring the controller to
WARNING:
loss of trailer braking. tow vehicle wiring and vehicle electronics.
the tow vehicle.
Follow wiring instructions.
Route the black wire through a grommet hole
Improper wiring will destroy the
WARNING: in the fire wall to prevent grounding and away
controller and void the manufacturer's warranty.
from the radio antenna to reduce any possible
The white wire must be connected to a
AM radio interference.
known good ground (preferably the negative
WARNING:
battery post).
To reduce the risk of injury or damage to
Improper or no ground will result in poor controller
property:
performance or lack of performance altogether.
» Always connect the white wire first and the
Improper ground connection can destroy the controller
black wire second.
and void the factory warranty.
» All four controller wires must be connected
properly for the controller to operate correctly.
» Failure to connect the wires correctly can cause
loss of trailer braking.
WARNING:

Leveling the G2 Controller

1. The G2 is self leveling. All 1999 and later Ford vehicles
without the trailer wiring package:
2. When the brakes are first applied, the G2 will
The red controller wire must be connected to the
read the level position before actual braking begins
light green wire of the brake stoplight through a
and apply the brakes proportional to the
20-amp in-line fuse.
deceleration.
Failure to install a 20-amp in-line fuse can
destroy the controller and void the
Special Conditions
manufacturer's warranty.
For tow vehicles equipped with factory trailer-
towing package:
» Refer to your vehicle owner's manual to determine the
correct connection points for the controller.
For vehicles without a trailer-towing package:
» Refer to the wiring diagram in fig. 4.
WARNING:
1989—1991 Ford Bronco, Econoline,
F-Superduty, and F150-350 Series:
The red stoplight wire MUST splice into the turn
signal connector harness and NOT in the
stoplight switch.
Connecting to the terminal of the stoplight
switch will break the switch and result in no
stoplights and no trailer braking.