Curt Manufacturing DISCOVERY Manual de usuario

PAGE 1

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

DISCOVERY

DISCOVERY BRAKE CONTROL

INSTALLATION AND USER GUIDE

51120-INS-R1 •

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This package includes:

(1) Brake control module with quick plug

(1) Mounting bracket

(4) Mounting bracket screws

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 - custom connector for specic vehicles. See catalog for availability

•CURT part# 51515 - male quick plug with pigtails

•CURT part# 51500 - brake control wiring kit

Key Features

•Display shows provides detailed brake force output

•Mount anywhere in your vehicle

(Dependable solid state electronics require no leveling)

•Electronic activation ensures smooth stops

•No internal moving parts

•Fully-adjustable power and time (sync)

•Provides automatic and manual trailer braking

•Manual control lever activates brake lights

•Compatible with electronic systems (anti-lock brakes and cruise control)

•Self diagnostic - continually monitors trailer connection and checks for short circuits

PAGE 3

Controls and Components

1. Display

2. Sync adjustment

3. Output adjustment thumb wheel

4. Manual control lever

5. Quick plug connector

PAGE 4

Output Control

The output control establishes the maximum

amount of power available to the trailer brakes.

As the output control is moved to the right, more power will be available

to the brakes when the brake pedal is pressed or the manual control is used.

The output control should be adjusted during initial setup, when trailer load

changes, when different trailers are used or to adjust for a change in road conditions.

The output setting is shown on the digital display when a trailer is connected and

the brake pedal is pressed or the when manual control lever is actuated. The output

setting is shown as 0 through 10, with 0 being the minimum and 10 the maximum.

Sync Control

The sync control is located on the right side of the brake control unit and is responsible

for adjusting trailer brake aggressiveness. The trailer brakes become more aggressive

as the switch is moved toward the rear of the tow vehicle.

To view the sync setting on the display, press the brake pedal (trailer must be connected)

and move the sync control slightly. The display will change to the sync mode.

The sync setting is shown as 1 through 9, with 1 being the least aggressive and 9 being

the most aggressive. The sync adjustment has no effect on the manual control. The sync

control should be adjusted for individual driver preference or changing road conditions.

PAGE 5

Manual Control

The manual control lever is located on the front left of the brake control unit.

It only applies to the trailer brakes. Manual control is used during initial setup and

in situations where a slow reduction in speed is desirable.

When the manual control is pushed to the right, the control begins to apply

the trailer brakes. The further to the right it is pushed the harder the brakes

are applied until the maximum set by the output control is reached.

The output setting will be shown on the display and can be adjusted when using the

manual control. The manual control activates the tow vehicle and trailer stoplights.

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.

Control activated

No trailer connected

Brake pedal pushed

Sync control activated

Trailer connected

Short or overloaded brake circuit

See trouble shooting guide

Internal control error

See trouble shooting guide

Control activated

Trailer connected

PAGE 6

Mounting the Brake Control

NOTE: Avoid mounting the brake control module near a CB radio or other RF transmitter.

Vertical

Horizontal

Any angle

PAGE 7

1. Determine a suitable mounting location.

Mount the unit securely to a solid surface where it is easily accessible to the driver.

The area behind the mounting location must be clear to prevent damage while drilling.

2. Hold the mounting bracket in the position selected

and mark hole locations through the slots in the bracket.

3. Using a 1/8" diameter bit, drill holes in the marked locations.

4. With a philips screwdriver, secure the bracket in place using the two

screws provided. Be careful not to strip the holes by over-tightening.

5. Mount the brake control unit in the bracket using the two

screws provided, as shown in the illustration on page 6.

Wiring

NOTE: Removal of factory supplied quick plug may void warranty.

Most pick-ups and utility vehicles are equipped with a plug from

the factory that allows quick brake control installation. Check the

owner's manual for plug availability, location and installation.

If the mating plug supplied with the vehicle is no longer available, a CURT

quick plug can be used. See the CURT catalog for application information.

For tow vehicles not equipped with a factory brake control plug,

we suggest CURT brake control wiring kit, part# 51500.

PAGE 8

IMPORTANT: Make sure that both positive and ground connections are made directly to

the tow vehicle's battery. Connecting to existing wiring or chassis ground, other than the

battery terminal, may damage vehicle circuits and could lead to trailer brake failure.

Mount a 30 amp, auto reset, circuit breaker as close to the battery as possible.

WIRING DIAGRAM

PAGE 9

IMPORTANT: When passing wire through sheet metal, always go through an existing

grommet, add a grommet or use silicone sealer to protect the wire from sharp edges.

Feed two 10 gauge, or larger, wires, one white and one 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 for connection 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. Using a 10/12 gauge butt

connector, attach the white wire from the battery area to the brake control's white wire.

Run a 10 gauge blue wire from the tow vehicle's trailer plug 'brake' terminal to the brake

control. Using a 10/12 butt connector, connect this wire to the brake control's blue wire.

Connect the brake control's red wire to the cold side

of the tow vehicle's stoplight switch using a wire tap.

NOTE: When making the stoplight switch connection on Ford / Mercury vehicles, do not

connect to the red wire with green stripe. Connect to the light green wire only.

For 1989 - 1991 Ford E and F series vans and trucks with anti-lock brakes, nd the

crescent shaped connector located on the steering column. The connector has two

rows of wires, the wire needed is the light green wire, second from the end in the

outside row. See the view shown in the wiring diagram on page 8.

For all other vehicles, use a test probe to nd the cold side of the stoplight switch. Probe

the switch wires until a wire is found that is only on when the brake pedal is pressed.

PAGE 10

IMPORTANT: Once a cold side wire is found, test to ensure that the wire is not grounded

when the pedal is in the up position. If the wire is grounded, the brake control unit will be

destroyed when manual control is used.

Reconnect the tow vehicle's negative battery terminal and attach the white, 10 gauge

wire previously positioned near the battery to the negative terminal using a ring terminal.

Using 10 gauge stranded wire and a ring terminal, connect the

'battery' side of the circuit breaker to the positive battery terminal.

Secure all loose wires with cable ties so that they will not be damaged and reconnect

the battery. See vehicle's owner's manual for special re-connection instructions.

To test installation, without a trailer connected, push the brake pedal. A single decimal

point ( . ) should light up on the display. If the decimal point does not light or if OL or Er is

shown on the screen go to the 'Troubleshooting' section.

Setup

Preliminary adjustments: With the trailer connected press and

hold the brake pedal, the display will show the output setting.

Adjust to 2.0 by turning the output control right or left as needed.

While still holding the brake pedal, move the sync control slightly. The display will change

to the sync setting. Adjust to 4o by sliding the sync control ahead or back as necessary.

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