Hayes 81725 Installation Manual

Mounting Angle & Direction
The Syncronizer can be mounted at any angle and in
any direction. It must be mounted in a location
where the driver can see the Red Indicator Light.
The driver must be able to reach and operate the
manual slide.
SYNCRONIZER
ELECTRONIC BRAKE CONTROLLER
HAYES BRAKE CONTROLLER P/N 81725
INSTALLATION MANUAL
For trailers with 2-4 electric brakes and
vehicles with 12 volt negative ground
systems only.
READ AND SAVE THESE INSTRUCTIONS
Controller Mounting and Installation
• Before beginning installation, read and become
familiar with these instructions.
• Leave these instructions in tow vehicle for future
reference.
• IMPROPER INSTALLATION AND OPERA-
TION COULD CAUSE PERSONAL INJURY
AND/OR EQUIPMENT AND PROPERTY
DAMAGES
• Questions on installation, adjustment, trouble
shooting or operation of brake controllers
• Call 800-892-2676 Monday through
Friday between 8:00 a.m. and 5 p.m.
Eastern Time.
SAFETY INFORMATION
Controller and Mounting Bracket
WARNING: Indicates a potentially
hazardous situation that, if not avoided,
• The bracket provided is to be used for mounting
could result in death or serious personal
the controller to the tow vehicle.
injury.
• Use the reversible slotted bracket.
CAUTION: Indicates a potentially
• Use only the provided screws to attach the
hazardous situation that, if not avoided,
bracket to the controller.
could result in damage to product or
property.
TIP: Contains helpful information to
facilitate installation.
operate correctly.
• Failure to properly connect all four wires can
cause loss of trailer braking.
• Improper wiring will destroy the controller and
void the manufacturer's warranty.
excessive vibration.
• Excessive vibration may result in poor perfor-
mance.
Installation Steps
1. Install the mounting bracket to a solid surface
under the tow vehicle dash using the two
machine screws and fasteners provided.
Tighten until snug. See Figure 2- Acceptable
Mounting Angles and Figure 3 - Attachment of
Mounting Bracket.
2. Insert four of the self tapping screws provided
through the mounting bracket holes and into the
desired controller anchor holes. Tighten until snug.
3. Mount in a location, which allows the driver to
easily apply the manual override and see the
Red Indicator Light.
Read all wiring instructions prior to making
electrical connections to the tow vehicle.
WARNING
To reduce the risk of injury or damage
to property:
• Always connect the white wire first and the
black wire second.
• 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:
• The white wire must be connected to a
known good ground (preferably the negative
battery post).
• Improper or no ground will result in poor
controller performance or lack of perfor-
mance altogether.
• Improper ground connection can destroy the
controller and void the manufacturer's
warranty.
WARNING:
• Improper connections may result in no
trailer brakes or destroy the controller and void the
manufacturer's warranty.
• Refer to the vehicle manufacturer or Hayes
Brake Controller at 1-800-892-2676 for the
latest controller red stoplight wire to stop lamp
switch connections.
WARNING:
Use of longer screws than those
provided can damage the unit and
cause loss of braking.
CAUTION:
Follow wiring instructions.
WARNING:
• Improper wiring will destroy the controller
and void the manufacturer's warranty.
• All four controller wires must be
connected properly for the controller to
CAUTION:
• DO NOT connect the black wire to any
CAUTION: vehicle power supply line or fuse panels that
could cause circuit overload or damage to
tow vehicle wiring and vehicle electronics.
• Care must be taken to ensure that the
• Route the black wire through a grommet
mounting surface is rigid enough to prevent
hole in the fire wall to prevent grounding
and away from the radio antenna to reduce
any possible AM radio interference.
TIP:
• Special Dual - Mated "Quik-Connect" Wiring Harnesses are available for all Hayes Brake Controllers fitted with a connector on the
wire leads, making connection a snap. Harnesses are available through all dealer resources. Ask specifically for the Hayes Brake
Controller Company (HBC) brand harnesses to match your controller.
The following chart describes the function of each of the controller's wires:
Order Color Function Wire Size Connect To
(AWG)
1st White Ground 16 grounded metal part of the firewall or directly to the negative (-) terminal of the battery. Connect this wire first.
2nd Black + connection to the vehicle's 12 positive (+) terminal of the battery. MUST have a self-resetting Circuit Breaker in-line between the controller and
power system the battery. See chart for proper size. Route the black wire through a grommet hole in the fire wall to prevent wire
grounding and away from the radio antenna to reduce any possible AM radio interference. Connect this wire second.
3rd Red Stoplight 14 non-powered stop lamp wire (of the stop lamp switch) or trailer tow wiring harness. It is recommended that a 20-amp
inline fuse be installed between the controller's red wire and the stop lamp switch. The fuse is required in 1999 & later Fords.
4th Blue Output to trailer brakes. 14 the trailer brake wire or tow vehicle / trailer connector.
IMPORTANT: Make all controller wiring connections to the wiring harness before connecting the harness to the vehicle.
SELF-RESETTING CIRCUIT BREAKER SIZE CHART
Number of Trailer Brakes
Number of Brake Light Bulbs
(tow vehicle Plus trailer)
2 Brakes
4 Bulbs (minimum) 20 AMP
5 Bulbs 20 AMP
6 Bulbs 20 AMP
7 Bulbs 30 AMP
8 Bulbs 30 AMP
9 Bulbs 30 AMP
Note: Each trailer brake magnet is assumed to draw 3 amps of current and
each brake lamp bulb is assumed to draw 2 amps.
APPENDIX
OEM TOW VEHICLE WIRING CONVERSIONS
CHRYSLER CONTROLLER FUNCTION
(THROUGH 2002)
RED W/BLACK TRACE BLACK +12 VOLT SUPPLY
WHITE W/TAN TRACE RED STOPLIGHT
BLUE BLUE TRAILER BRAKES
BLACK WHITE GROUND
FORD (THROUGH 2002) CONTROLLER FUNCTION
RED BLACK +12 VOLT SUPPLY
LIGHT GREEN RED STOPLIGHT
BLUE BLUE TRAILER BRAKES
WHITE WHITE GROUND
BROWN NOT USED ILLUMINATION
FORD EXPEDITION CONTROLLER
RED BLACK
RED/GREEN TRACE RED
BLUE BLUE
BLACK WHITE
GENERAL MOTORS CONTROLLER
RED BLACK
LIGHT BLUE RED
DARK BLUE BLUE
BLACK WHITE
BROWN NOT USED
2004 INFINITY CONTROLLER
RED BLACK
RED/GREEN RED
BROWN/WHITE BLUE
BLACK WHITE
RED/BLUE NOT USED
RANGE ROVER CONTROLLER
REMOVE TAIL LIGHT AND BLACK
CONNECT RED RED
CONTROLLER WIRE TO BLUE
BLACK/BLUE TRACE, NO WHITE
LIGHT WITH MANUAL NOT USED
2004 TITAN/ARMADA CONTROLLER
RED BLACK
RED/GREEN RED
BROWN/WHITE BLUE
BLACK WHITE
RED/BLUE NOT USED
2004 TOYOTA TUNDRA CONTROLLER
BLACK-RED BLACK
GREEN-WHITE RED
RED BLUE
BROWN WHITE
Special Conditions
For tow vehicles equipped with factory trailer
4 Brakes
towing package:
30 AMP
• Refer to your vehicle owner's manual to deter-
30 AMP
mine the correct connection points for the
30 AMP
controller.
30 AMP
30 AMP
• See Appendix section for partial list of manufac-
40 AMP
turer wiring harness to controller conversions.
For vehicles without a trailer-towing package:
refer to the wiring diagram in Figure 4.
CHRYSLER (NEW)
WHITE W/ RED TRACE
BLUE W/WHITE TRACE
BLUE
GREEN W/BLACKTRACE
FORD (NEW)
PINK
RED
BLUE
WHITE
BROWN
FUNCTION
+12 VOLT SUPPLY
STOPLIGHT
TRAILER BRAKES
GROUND
FUNCTION
+12 VOLT SUPPLY
STOPLIGHT
TRAILER BRAKES
GROUND
ILLUMINATION
FUNCTION
+12 VOLT SUPPLY
STOPLIGHT
TRAILER BRAKES
GROUND
ILLUMINATION
WARNING:
1989 - 1991 Ford Bronco, Econoline, F-
FUNCTION
Superduty, and F150-350 Series:
+12 VOLT SUPPLY
• The red stoplight wire must splice into the
STOPLIGHT
turn signal connector harness and NOT in the
TRAILER BRAKES
GROUND
stoplight switch.
ILLUMINATION
• Connecting to the stoplight switch will break the
switch and result in no stoplights and no trailer
FUNCTION
braking.
+12 VOLT SUPPLY
STOPLIGHT
WARNING:
TRAILER BRAKES
GROUND All 1999 and later Ford vehicles
ILLUMINATION without the trailer wiring package:
• The red controller wire must be connected
FUNCTON
to the light green wire of the brake stop light
+12 VOLT SUPPLY
through a 20-amp inline fuse.
STOPLIGHT
• Failure to install a 20-amp fuse can destroy the
TRAILER BRAKES
controller and void the manufacturing warranty.
GROUND
Form # 7-2167
19003-3H