D-Celerator® Unified Tow Brake Installation Instructions
Protect your investment
Connections Between the Motorhome and the Towed Vehicle
Two connections between the coach and the towed vehicle must be completed beforeoperating the Unified Tow Brake.
First, plug the wiring umbilical harness connectors to the mating connectors at therear of the motorhome and the front of the towed vehicle. This harness contains wiringto supply a charge to the towed vehicle, and to carry the braking signal to the powermodule. Make sure the motorhome can make sharp right and left turns without strainon the umbilical cord.
Also, the lanyard from the breakaway switch on the towed vehicle must be attachedto the rear of the motorhome. In a breakaway situation, the switch will activatefull braking in the towed vehicle. There should be no obstacles or strain on thelanyard cable to the motorhome. Also, make sure the motorhome can make sharp rightand left turns without strain on the lanyard cable. Be certain that the breakawayswitch is allowed to swivel so that the switch is always in a straight line withthe lanyard. Do not let lanyard cable drag on the ground. Fasten lanyardto motorhome frame – not on safety chains, tow ball, or towing hitch system.
If the towed vehicle is equipped with adjustable pedal assemblies, the brake pedalassembly should be adjusted closest to the driver seat when towing. Check to be surethe brake lamps are not illuminated. If the Unified Tow Brake has been installedcorrectly, the brake lamps should not be illuminated.
Any time you are driving your towed vehicle, the harness and the lanyard should becompletely removed from both vehicles and stored in a secure location. An additionalpin is provided in the kit on a key ring to place in the breakaway switch to releaseyour towed vehicle’s brakes. This pin is simply a convenience for you so that youdon’t have to leave the lanyard pin in the switch with the cable rolled up when youare driving your towed vehicle. Also included in the kit are two Electrical ConnectorCovers to plug into the wiring harness connectors at the rear of the motorhome andthe front of the towed vehicle when you are driving your motorhome or towed vehiclesolo.
Inside the Motorhome
The light bar on the remote control serves several purposes:
• When the wiring between the motorhome and the towed vehicle is connected and thecircuit is complete, the green LED will illuminate. NOTE: The green LED must beilluminated when the Tow Brake is in use. If the green light is not on, the tow brakeis not functioning.
• The series of red LEDs indicates the amount of brake effort being applied in thetowed vehicle. These lights are activated whenever a braking instruction is sentto the towed vehicle (when motorhome brakes are applied or when the manual overridelever is depressed).
• Finally, if the good wiring connection between the coach and the towed vehicle is lost, the green light will go out and a beep will be emitted from the controller.
You will also get a beep from the controller if the towed vehicle brakes are appliedwithout a signal from the controller. If you hear the beep, pull off the road andstop as quickly as possible.
When you depress the brake pedal in the motorhome the Unified Tow Brake automaticallyactivates the brakes in the towed vehicle. The amount of proportional braking inthe towed vehicle is easily adjusted using the gain knob on the top of the remotecontroller.
Setting the gain level is like setting the gain on electric trailer brakes. The standardgain setting will be the highest level which will cause the towed vehicle’s wheelsto slide in loose gravel when the brakes are applied, but will not skid on hard pavement.With a high gain setting, you will feel more braking from the towed vehicle. At alow gain setting you will feel less braking effort in your towed vehicle. Set thegain knob to the setting that gives you the brake effect you like. The numeric indicatorson the gain control knob will assist you if you would like to have different settingsfor different driving conditions. When your driving conditions change, you couldthen quickly set the gain knob to your previously selected location.
Test the Breakaway Switch on a Regular Basis and Make Sure the Lanyard CableIs Not Damaged
When testing the switch, disconnect umbilical cord from towed vehicle. Pull lanyardpin out of the breakaway switch. This will take approximately 20 lbs. of pull. Youshould hear the vacuum pump running and the brake pedal will be activated.
When test is completed be sure back of lanyard pin is flush with the switch. Theblack washer should disappear. Reconnect umbilical cord to motorhome.
The manual thumb lever on the remote control allows you to activate the brakes inthe towed vehicle without applying brakes in the Motorhome.
Before driving your motorhome using the Unified Tow Brake, be sure that all wiringharness connections and breakaway switch lanyard between the two vehicles are attachedand are secured so that neither is allowed to drag the ground or is pulled/stretchedwhen making a hard left or right turn. Place the ignition switch in the towed vehiclein its normal position for towing which unlocks the steering wheel.
Testing the Wiring of Your Controller to the Brake Light Switch
Perform this simple check to see if your Brake Controller is being affected by theemergency flashers. You do not need to be moving to perform this check. With yourtowed vehicle and Unified Tow Brake connected to your motorhome, activate your "emergencyflashers." If the red lights on the Brake Controller flash in conjunction withthe emergency flashers, your Brake Controller is wired into a location of the brakelight switch which is energizing your brake lights. If this condition exists youmay use your emergency flashers only if your motorhome is standing still. Under nocircumstances should you use the emergency flashers while the motorhome is in motionuntil the wiring is corrected.
If your motorhome is equipped with a "factory-installed" exhaust brake,you can perform the same system check, but instead of turning your emergency flasherson, activate your exhaust brake. Again, you do not need to be moving to perform thischeck. If the red lights on the Brake Controller light up, your Brake Controlleris wired into a location which energizes your brake lights. In this case you shouldnot use your exhaust brake while towing until the wiring is corrected in your motorhome.
INSIDE THE TOWED VEHICLE
1. The solenoid is set at the factory, but it is possible that, during shipping,the solenoid could move out of adjustment. To verify the correct setting for thesolenoid, pull the plunger all the way back and measure from the end of the machinedclevis to the face of the stop plate. The measurement (gap) must be exactly 1-3/8".The Unified Tow Brake will not function properly if the 1-3/8" measurement isexceeded.
2. Locate an area to place the solenoid assembly. The primary consideration in placingthe solenoid is that it is out of the way when driving the towed vehicle. A secondaryconsideration is that the solenoid is hidden from view. In most installations thepreferred location is high on the floorboard under the dash on the passenger side,but practically any location is acceptable (for example, under the driver's seat,beside the driver's seat, behind the driver's seat, in front of the driver's seat,under the passenger seat, under the back seat, in the trunk) as long as you havesufficient cable to reach the brake pedal from the solenoid.
Once you have determined the location of the solenoid, use the 1/4” x 1” self tappingscrew to anchor the solenoid so that it does not move around the passenger compartmentof the towed vehicle.
The cable assembly included in the kit is 4’ long. Longer cable assemblies are available.If you prefer an 8’ (part # CA-6081) or 12’ (part # CA-6121) cable assembly, youmay order them from your selling dealer or from U.S. Gear.
The solenoid does NOT have to be in a straight line with the brake pedal. Remember,the most important factor in placing the solenoid is the operation of the towed vehicle.Be sure that the solenoid, and all the components of the Unified Tow Brake are outof the way for driving the towed vehicle after it has been separated from the motorhome.
Before mounting the brake pedal bracket, perform the following procedure to ensureproper operation of the Unified Tow Brake. If the towed vehicle is equippedwith adjustable pedals, install this product with the brake pedal assembly adjustedclosest to the driver seat. (Refer to Fig.1)
1. Start the towed vehicle’s engine. Using a ruler, locate a reference point on thebrake pedal bracket which appears to give a 11/4" stroke from a relaxed brake pedal to brake-applied.
2. Apply pressure to the brake pedal with your little finger (pinky) until brakesare applied. Measure the distance the reference point moved.
3. If there is more than a 11/4" stroke at your reference point, slide yourpoint up the pedal bracket. If the stroke is less than 11/4", slide the pointdown the pedal bracket. Note: Mount the bracket as low as possible on thebrake pedal lever while maintaining the 11/4" stroke.
4. If a stroke of exactly 11/4" cannot be achieved, fine adjustment can be accomplishedwith the threaded button at the end of the inner cable.
To verify that the pedal stroke is adjusted properly, use the following procedure.With the towed vehicle engine running (idle), and the breakaway switch applied (plungerremoved from switch), put the transmission in gear. The towed vehicle (only) shouldnot move against its own power. If the towed vehicle moves, then the brake pedalbracket will need to be moved closer to its pivot point to achieve the desired results.Note: This test can be performed when the towed vehicle installation is completed.
3. Slit the carpet 7" to 8" in front of the solenoid bracket to slide thecable through.
4. Pull the carpet up to expose the insulation on the floorboard of the driver side.Remove the rocker panel if necessary to gain access to the edge of the carpet.
5. If the towed vehicle is equipped with adjustable pedals, install this productwith the brake pedal assembly adjusted closest to the driver seat. Afteryou have determined the location on the brake pedal bracket which allows the 11/4"stroke, place the mounting bracket on the brake pedal and attach it using the twoscrews supplied. The mounting bracket can be placed on either side of the brake pedalbracket. IMPORTANT: Before securing the brake pedal bracket, project a verticalline from the pivot point (it may not be possible to actually see the pivot) downthrough the area that you are placing the brake pedal bracket. Then place anythingwith a 90-degree corner on it (piece of cardboard, triangle, etc.) on the top ofthe block and slide the backside (vertical) to that imaginary line and tip the blockup and down until it lines up. It is important to pull the brake pedal at a 90-degreeangle from the pivot point to achieve maximum pull force from the solenoid. (SeeFig. 2)
6. Establish a location for mounting the pulley, but do not attach the pulley. NOTE:Be sure the brake pedal will not make contact with the pulley when full braking isapplied to the pedal. Move the pulley bracket to the left or right on the firewallto avoid contact with the brake pedal.
7. Slit the carpet under the dash just behind the location of the pulley to providean opening for the cable to enter.
8. Center the small cylinder at the solenoid end of the cable in the support bracketon the solenoid plate. Place the cable into the slot in the support bracket to completethe connection of the cable to the solenoid assembly. Tighten the #5 Allen screwsnug against the ferrule at the end of the outer cable which you have dropped intostop block slot.
9. Guide the cable assembly through the slit in the carpet in front of the solenoidand up through the slit behind the pulley location.
10. Place the brake pedal end of the cable in the slot on the side of the brake pedalbracket and screw the threaded ferrule into the brake pedal bracket.
11. Mount the pulley system in the location you determined in step 6 against the inside of the firewall behind the brake pedal. To mount the pulley you will need to "straddle" the inner cable with the pulley bracket with the pulley pin hole on the side farthest from the stop bracket. Then attach the pulley using the four self-tapping sheet metal screws supplied. Before fastening the screws, be sure there are no vehicle components on the engine side of the firewall which could be damaged by the screws (booster, brake line, etc.). Insert the pulley pin through the hole in the pulley bracket and secure with the pin clip.
12. Be sure to leave approximately 1/4" of slack in the inner cable. Then mountthe outer cable support bracket in a location which is in a straight line with thepulley. The outer cable support bracket can be at any length below the pulley. Theway to determine its proper location is to slide the bracket over the ferrule atthe end of the outer cable until the ferrule bottoms out in the hole of the supportbracket. Tighten the #5 Allen set screw snug against the ferrule on the end of theouter cable in the support bracket.
13. Determine the layout of the cable assembly on the floorboard or firewall. Thecable assembly can be routed across the floorboard to compensate for any excess length.You may curve or loop the cable assembly with a big, sweeping radius, but be surenot to have any tight radius curves or loops in the cable which would cause the cableassembly to bind or hang up when the tow brake is being used.
14. Once you have determined the layout of the cable assembly, score the insulationand place the cable in the slot to allow the cable to lay flat on the floorboard.
15. Lay the Power Module under the dash out of the way. The Power Module will besecured under the dash at the end of the installation procedure using wire ties.Leave the carpet pulled back and the rocker panel exposed until installation is completed.
16. Once these connections have been completed in the towed vehicle, check tomake sure that the brake pedal is in a completely relaxed position when the systemis not in use. One way to double check is to make sure that the towed vehicle’sbrake lights are not lit. If necessary, make fine adjustments to the inner cableusing the threaded ferrule you have screwed into the brake pedal bracket.
UNDER THE HOOD OF THE TOWED VEHICLE
1. Mount the vacuum pump as close to the power brake booster as possible. The vacuumpump can be secured to an existing hose or wiring harness using wire ties.
2. Cut the 3/8" or 1/2" I.D. hose from the engine to the brake boosterand install the appropriate-sized T-connector. Install the appropriate-sized checkvalve between the engine and the T-connector. Make sure the flow arrow on the checkvalve is pointing toward engine.
3. Run the supplied vacuum pump tube from the vacuum pump to the T-connector. Connectthe tube to the nozzle marked "In" on the vacuum pump. The nozzlemarked "Out" will not have anything connected to it. Cut the tube to theappropriate length and attach to the T-connector.
4. Mount breakaway switch on horizontal plane of the towed vehicle frame. There shouldbe no obstacles or strain on the lanyard cable to the motorhome. Also, make surethe motorhome can make sharp right and left turns without strain on the lanyard cable.
5. The breakaway should be bolted to the frame with 1/4" bolt that will allowthe switch to swivel. Be certain that the breakaway switch is allowed to swivelso that the switch is always in a straight line with the lanyard.
6. Do not let lanyard cable drag on the ground. Fasten lanyard to motorhomeframe – not on safety chains, tow ball, or the towing hitch system.
7. Mount the 40 amp Circuit Breaker close to the battery with the two screws supplied.
8. Following the wiring details in the middle of this booklet attach the Harnessand Wires under the hood of the towed vehicle.
NOTES on Wiring (refer to Component List):
a) The red 12 gauge wire is the 12 volt power wire. IMPORTANT: Be sure to leave thered wire that runs from the "battery" side of the circuit breaker to the"positive" post of the battery unconnected until the rest of the installationof the Unified Tow Brake is complete.
b) For easier installation, the blue and yellow 18 gauge wires which plug intothe four position connector are are not installed into the connector before shipping.Run the blue and yellow 18 gauge wires from the engine compartment through the firewalland insert the metal terminals into the connector with the white and gray wires asshown in the component rendering in the center of the booklet. Be sure the wiresare seated properly in the connector. Note: Once the wires are inserted into theconnector, they will not come back out.
c) If towed vehicle has been wired for auxiliary lights, or when the towed vehicle was wired for towing you know for sure that blocking diodes were added to protect feedback from the towed vehicles’ brake lamps, the action described in this paragraph are not necessary. If the motor home lamps are tied into the factory towed car brake lamps, and NO blocking diodes are installed, complete the following step. Locate the towed vehicle’s brake light switch. It may have several wires. With the ignition in the "ON" position, use a test light to find the 12 volt supply wire that feeds power to the switch at all times. (This is the only wire that is "hot" in all cases.) Cut the 12 volt power wire and attach the gray and white wires to the two ends of the wire with the butt connectors supplied. It doesn't’t matter which of the two wires is connected to which end of the power wire. This action will deactivate the brake light switch when the Unified Tow Brake is armed.
d) The black 12 gauge wire (Power Module ground) and the Vacuum Pump ground wireand the blue 16 gauge wire (Breakaway Switch ground) are separate from the harness.For the Vacuum Pump and Breakaway Switch ground wires, be sure to scrape downto bare metal in the area of your ground screw on the vehicle body before attachingthe ground wires. The Power Module ground wire must be grounded to the negative postof the towed vehicle battery.
e) The Power Module ground (12 ga. black), the Electric Solenoid wire (12ga. brown),and the Vacuum Pump/Solenoid wire (16 ga. violet/12 ga. red) all attach to the frontof the Power Module.
1. Using wire ties, attach the motorhome harness umbilical connector to the lightingreceptacle at the rear of the motorhome.
2. Before running the harness to the front of the motorhome, locate the motorhomechassis battery.
a) On rear-engine coaches: The chassis battery is normally located in theengine area, or at least in the rear-half of the coach. Remove the red 14 ga. chargewire from the harness lume in the area of the chassis battery and connect chargewire to the positive post of battery.
b) For front-engine coaches: The chassis battery is normally located at thefront of the coach. Leave the red charge wire in the wiring harness loom to attachto the positive post of the battery.
Run the balance or entire wiring harness to the front of the motorhome and threadthe connector through the firewall into the cabin under the dash on the driver side.
NOTE: Be sure that the wiring harness is not placed near any source of extremeheat (manifold, exhaust system, etc.) under the motorhome.
3. Attach the controller to the gear shift lever, or use the dash mount suppliedto place the controller at a convenient location. Wrap electrical tape around thegearshift lever or dash mount post to assure a tight grip. (Refer to the ControllerAngle supplement included in the package with controller.)
4. Run the 2’ harness from the controller to the connector of the main harness underthe dash. Plug the connectors of the two harnesses together.
5. Mount the 20 amp circuit breaker in the engine compartment close to the chassisbattery with the two screws supplied.
6. Refer to the wiring details in the middle of this booklet to attach the wiresin the motorhome.
NOTES on the Wiring (refer to Component List in the middle of this booklet):
a) The red 12 gauge wire is the 12 volt power wire. IMPORTANT: Be sure to leave thered wire that runs from the "battery" side of the circuit breaker to the"positive" post of the battery unconnected until the rest of the installationof the Unified Tow Brake is complete.
b) The 18 ga. Red Wire is the Ignition Wire. IMPORTANT: LOCATE AFUSE POSITION THAT IS "HOT" ONLY WHEN THE IGNITION IS "ON".
c) The Black Wire is the Ground Wire. Be sure to scrape down to bare metalin the area of your ground screw on the vehicle body before attaching the groundwire.
d) The Orange Wire connects to the "cold" side of the brake light switch/airswitch.
GASOLINE CHASSIS APPLICATION: The brake light switch is found under the dash up atthe top of the brake pedal lever arm.
DIESEL CHASSIS APPLICATION: The air brake switch is normally found in one of twoplaces. First, look to see if the brake pedal lever under the dash of the motor coachgoes through the floor or out through the front bulk-head. If the pedal lever goesthrough the floor, the air switch can be accessed from the driver-front wheel wellarea. If the pedal arm goes through the bulk-head, the air switch can be accessedon the outside of the bulk-head.
With the motor home ignition in the "ON" position, use a test light tolocate a wire on the brake switch/air switch which is "hot" only when thebrake pedal is depressed, and "cold" when the pedal is released (some latemodel Roadmaster chassis’s use a "negative" switched air switch. Referto the Roadmaster Chassis supplement for those applications).
GASOLINE CHASSIS: You may have more than one wire that reacts "cold/hot".Once you have found the wire(s) that react this way, we then must identify the onewhich controls the brake lights on the back of the motor home. The only way to dothis, other than contacting your chassis manufacturer to see if they can tell youwhich wire, is to cut a "cold/hot" wire and apply the brake pedal and seeif the brake lights on the rear of the motor home is dead. If so, this is the correctwire. If the brake lights are still working, then the wire you cut is not the correctwire that controls the brake lights and must be re-connected and then proceed tocut another wire that is "cold/hot" and again check to see if the brakelights are off or not until you have correctly identified the brake light wire (NOTE:The reason you may find multiple wires that are "cold/hot" is because ofother accessories utilizing the brake light switch. Such as the cruise control, torqueconverter lock-up, ABS, etc.).
GASOLINE AND DIESEL CHASSIS: Once you have identified the correct "cold/hot"wire from the brake switch/air switch, connect the Orange wire from the Controllerand install the Blocking Diode supplied with the kit to the factory wire. Instructionsfor the Blocking Diode Installation are packaged withthe Diode. Be sure to install the Blocking Diode as close to the brake switch/airswitch as possible and that there are no other wires between the brake switch/airswitch and the Diode.
COMPLETING CONNECTIONS IN TOWED VEHICLE
1. After connecting the towed car harness to the electric solenoid, route the harnessalong the rocker panel or under the carpet. Re-install carpet and rocker panel whichwere removed earlier in the installation.
2. Before using the Unified Tow Brake, attach the tow bar, safety chains, breakawaylanyard, and umbilical cord(s) between the towed vehicle and the motorhome. Makesure the motorhome can make sharp right and left turns without strain on the umbilicalcord or lanyard.
After completing the installation and making all the wiring connections, performthe following tasks to ensure proper operation of the Unified Tow Brake.
After the breakaway switch has been installed and wired, slowly pull out pin andmake sure brakes engage. Push the pin back into switch until the flange on the pinis against the switch and the black neoprene washer disappears. Do not leave thebreakaway switch activated for more than 2-3 minutes at a time while testing.
With the ignition of the motorhome in the "ON" position,
1. the green light on the far right of the controller should be illuminated. Thislight indicates that the circuit is complete.
2. depress the motorhome brake pedal or press down on the manual thumb lever on thecontroller. You should hear the vacuum pump in the towed vehicle running. (The vacuumpump will continue to run for 20 seconds after the brake pedal or thumb lever isreleased.) Also, the brake pedal and the solenoid in the towed vehicle should movewhen the thumb lever is depressed. NOTE: The motorhome/towed vehicle combinationmust be in motion to check to see if the brake pedal in the towed vehicle moves whenthe brake pedal is depressed in the motorhome. The brake pedal in the towed vehiclewill NOT move when you depress the brake pedal in the motorhome if the rig is stationary.
3. after test driving, check the brake lights on the towed vehicle to make sure theyare off. This will confirm that the brake pedal is rebounding completely to an "off"position. (If brake lights in the towed vehicle are on, check for inner cable binding,or some other mechanical impediment which is causing the brake pedal to remain partiallydepressed when the brakes are released.)
4. unplug the umbilical cord. The green light on the controller should go out anda beep will be emitted from the controller. This indicates that the circuit is broken.(This result will also occur in a breakaway situation.)
After completing system check, be sure that all wiring harness connections and breakawayswitch lanyard between the two vehicles are attached and are secured so that neitheris allowed to drag the ground or is pulled/stretched when making a hard left or rightturn.
Besure to give the customer the spare breakaway switch pin, key ring, and two (2) electricalconnector plugs and the Customer Information Envelope which contains warranty registrationcard and warranty policy.
This completes the installation of the U.S. Gear D-Celerator® Unified Tow Brake.
Item Part Number Description Quantity
1 EC-4115A Wiring Harness (Motorhome Side) 1
2 TC-6000 Control Module 1
3 LP-6060 Breakaway Lanyard 6' 1
4 BS-6000 Breakaway Switch 1
5 EC-4115B Wiring Harness (Connector) 1
CV-6120 Check Valve 3/8"
Check Valve 1/2" 1
TF-6516 Tee Fitting 3/8"
Tee Fitting 1/2"
Tee Fitting 5/16" 1
8 VH-6000 Vacuum Hose 7/32" x 24" 1
VP-6000C Vacuum Pump
Vacuum Pump Cover 1
10 TS-6000 Self-Tapping Screw 1/4" x 3/4" 2
11 SS-6002 #5 Allen Set Screw, 1/4" 1
12 UTBJ02155 Flat Block Pulley 1-1/2" O.D. 1
13 TS-6001 Self Tapping Screw 3/16" x 3/4" 4
14 ST-6003 Outer Cable Stop Bracket 1
15 UTBJ02241 Brake Pedal Bracket Adjust Side 1
16 UTBJ02240 Brake Pedal Bracket Clamp 1
17 LW-1001 Lock Washer 1/4" 2
18 SH-6000 Socket Head Cap Screw 1/4-20 x1 2
19 EC-4115E Wiring Harness (Car Side) 1
20 PM-6001 Power Module 1
CA-6121 Cable Assembly 4'
Cable Assembly 8' (not shown)
Cable Assembly 12' (not shown) 1
22 UTBJ02242 Solenoid End 1
23 JN-1000 Jam Nut 5/16-24 1
24 ST-6001 Solenoid Stop 1
25 SS-6003 #5 Allen Set Screw, 5/8" 1
SH-6001 Lock Washer 5/16"
Socket Head Cap Screw 5/16"-18 x 3/4" 2
27 PL-6000 Solenoid Plate 1
28 CB-1002 Carriage Bolt 5/16"-18 x 5/8" 4
29 LN-1003 Lock Nut 5/16"-18 4
30 ES-6001 Electric Solenoid 1
31 PC-1002 Hairpin Clip 1
32 CP-1002 Pulley Pin 1
Part Number Description Quantity
RH-5161D Hose, 5/16" I.D. x 2" 1
BD-6000K Blocking Diode Kit 1
DM-4056 Double Faced Tape for Dash Mount 2
DM-6000 Dash Mount for Controller 1
DP-6000 Spare Plunger Only 2
EC-4115D Electrical Connector Plugs 2
KR-6000 Key Ring for Extra Breakaway Pin 1
LW-1001 Lock Washer 1/4" for Breakaway Bolt 1
NT-1100 Nylon Ties 20
SB-6000 Breakaway Switch Bolt 1
SN-6000 Nut for Breakaway Bolt Pin 1
TS-6001 Screws for mounting Circuit Breakers 4
TS-6002 Self Tapping Screw, 1/4" x 1" 1