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Brake Actuating Systems

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This section consists of various ways to ac ti vate and actuate your trailer brakes and includes the following: Electric Controls, Breakaway Kits, Hydraulic Surge Ac tu a tors, Plumbing Line Kits, Electric/Hydraulic
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This section consists of various ways to ac ti vate and actuate your trailer brakes and includes the following: Electric Controls, Breakaway Kits, Hydraulic Surge Ac tu a tors, Plumbing Line Kits, Electric/Hydraulic and Ac tu at ing Sys tems for Air/Hydraulic or Straight Air. Electronic Controls... L-2-L-6 Control Installation Kits... L-7 Control Accessories... L-8 Side-Post Mount Battery Adapter Kit... L-8 The Engager Breakaway Kit... L-8 Breakaway Kits... L-9 Breakaway Kit Accessories... L-10 Actuators: Carlisle Hydrastar Elec-Hyd Actuators...L-11 Demco Hydraulic Actuators...L-12 & L-13 Titan Actuators... L-14 Atwood Actuators... L-14 Balcrank Actuators... L-14 Dexter Elec/Hyd Actuator... L-15 Hydraulic Line Kits... L-15 Air Trailer Kits... L-16 ABS Air Trailer Kits... L-17 Air/Hydraulic Trailer Kits... L-17 Miscellaneous System Parts... L-18 Hydraulic Fittings... L-19 Hydraulic Lines and Brackets... L-19 Dexter Electric Trouble Shooting Guide... L-20 Section L-1 Voyager Features Include: Plug & Play Controls True Proportional Braking Power: Inertia Activated Sensor. Two Control System: Controls power output to brakes and braking response. Manual Override: Aids in setting controls and allows manual application of brakes. LED Light Display: Indicates a completed electrical circuit, aides in setting controls, changes from green to red indicating relative braking power. Installation: Mounts conveniently under vehicle dash. Warranty: Limited 5 year warranty. PART NO. REF. NO. DESCRIPTION 9030A NEW VOYAGER, ALL ELECTRONIC FOR 1-4 AXLES Primus IQ Features Include: True Proportional Braking Power: Inertia Activated Sensor, no manual leveling. Two Control System: Controls power output to brakes and braking response. Manual Override: Aids in setting controls and allows manual ap pli cation of brakes. Digital Display: Shows voltage to trailer during braking, plus diagnostic features. Installation: Control design allows multiple angles of control positioning. Warranty: Limited lifetime warranty PRIMUS IQ, ALL ELECTRONIC FOR 1-3 AXLES Prodigy P2 Features Include: Section L-2 True Proportional Braking Power: Inertia Activated Sensor, no manual leveling. Two Control System: Controls power output to brakes and braking response. Manual Override: Aids in setting controls and allows manual ap pli cation of brakes. Digital Display: Indicates voltage readout and NC (no connection) if connection is missing Visual warning if trailer becomes disconnected. Installation: Control design allows multiple angles of control positioning. Warranty: Limited lifetime warranty PRODIGY P2, 1-4 AXLES REPLACEMENT POCKET BRACKET ONLY FOR PRODIGY CONTROL REPLACEMENT PLUGIN HARNESS FOR 90160/90195/90885 Controls Prodigy P3 Features Include: True Proportional Braking Power: Inertia Activated Sensor, no manual leveling. Two Control System: Controls power output to brakes and braking response. Manual Override: Aids in setting controls and allows manual application of brakes. Digital Display: Distinct, easy to see LCD display with multiple color and contrast options. Installation: Compact, dash hugging design, unique, easy-to-use, clip mounting system. Electric/Hydraulic: Allows the user to switch between Electric and Electric Over Hydraulic trailer brakes. Warranty: Limited lifetime warranty BRAKE CONTROL, TEKONSHA P-3, 1-4 AXLES Prodigy RF Features Include: Perfect for use with shared trailers: Rental, Fleet or when multiple tow vehicles are available. True Proportional Trailer Braking: Forward or reverse, no level adjustment necessary. Remote Hand Held Unit Features Include: Wireless Communication: between the remote Hand Held Unit (90251, included) and Trailer Power Module eliminates the need for under the dash wiring. No drilling, brackets or clips required. Easy to use Remote Hand Control: includes the Prodigy Boost system to allow for different levels of customized braking. Unit plugs into any standard 12 volt power accessory adaptor. Continual Diagnostic Scanning: with a visual warning in the hand display should a fault condition occur. 5-Year Limited Warranty: on Hand Held Unit. Trailer Mount (Power Module) Unit Features Include: Trailer Power Module is Watertight: and includes a sealed 8 7-Way vehicle connector. Multiple Mounting Options: on the tongue or front of the trailer. Module Powered: through 7-Way Cable from the Tow vehicle. 15-Year Limited Warranty: on the trailer mounted power module (1-Year Limited Warranty on Cord) PRODIGY RF, 1-3 AXLES HAND-HELD MODULE FOR PRODIGY RF, BRAKE CONTROL Section L-3 Energize III & Energize XPC Features Include: 81741B True Proportional Braking Power: Inertia Activated Sensor Two Control System: Controls power output to brakes and braking response. Manual Override: Aids in setting controls and allows manual ap plica tion of brakes. LED Light Display: Indicates there is a completed electrical circuit, and informs operator of vehicle s braking response and relative braking power. Installation: Mounts conveniently on top or under vehicle dash. Warranty: Limited 5 year warranty Syncronizer Features Include: PART NO. REF.NO. DESCRIPTION 81741B ENERGIZE III, ELECTRIC BRAKE CONTROL, 1-2 AXLES ENERGIZE XPC, ELECTRIC BRAKE CONTROL, 1-3 AXLES Time Actuated Power: Trailer brakes are gradually applied at preset rates. Full brake actuation in about 2.5 seconds. 100% solid state. Digital Display: Displays voltage being applied to brakes; presence of short circuit and trailer connection. Manual Override: Aids in setting controls and allows manual brake actuation. Installation: Mounts in any position, no leveling required. Digital readout can be reset for installation requiring upside down mounting. Warranty: Limited lifetime warranty. PART NO. REF.NO. DESCRIPTION BRAKE CONTROL, HAYES SYNCRONIZER, 1-2 AXLES G2 Features Include: Self-leveling: Tri-axis accelerometer measures the rate of deceleration or gravitational pull on 3 planes - front-to-rear, left-to-right & up-down. Proportional Braking in reverse without using manual lever. Plug & Socket: Allows unit to be removed and stored when not in use. Universal QUIK-RECEIVER Mounting Sleeve: Uses VHB tape for mounting; no screws or tools required. LCD Display: Large and easy to read: displays battery, stoplight & output voltage. Screen color, intensity and contrast can also be adjusted. Alarm Mode: Exclusive audible tone warns of any trailer braking related fault. Ease of Use: Allows use of electric trailer brakes or hydraulic drum or disc; simply change setting using LCD screen & up/down buttons. Boost Feature: Provides easier adjustment based on the weight of trailer being towed by increasing initial brake gain by 5% to 20%, depending on setting selected. Section L-4 PART NO. REF.NO. DESCRIPTION 81792K BRAKE CONTROL, HAYES G2, 1-4 AXLES Dexter Control Predator Features Include: True Proportional Braking Power: Inertia Activated Sensor. Two Control System: Controls power output to brakes and braking response. Manual Override: Aids in setting controls and allows manual ap pli ca tion of brakes. LED Display: Large digital LED displays voltage output, and makes leveling quick and easy. Mounting Range: Versatile mounting range of -35º to +90º, to accomodate a wide variety of vehicle interiors. Warranty: Limited 7 year warranty. PART NO. REF.NO. DESCRIPTION PREDATOR DX2 BRAKE CONTROL FOR 1-2 AXLES The Warner Air Utility Control interconnects with air brake systems of tow vehicles and automatically op er ates electric trailer brakes in sychronization with air brakes. It may be used in FMVSS 121 systems. The manual override feature operates trailer brakes only. Warner Air Utility Control The unit displaces only 2.8 cubic inches of air at 100 PSI. It is ad just able for a wide range of vehicle brake system pres sures, with low pressure sensitivity that assures im me di ate and smooth engagement of trailer brakes. The special design of the internal mul ti ple resistor pack provides heat sinking and heat dis si pa tion char ac ter is tics. For use on trailers with up to 8 brakes (4 axles) AIR OPERATED FOR AIR BRAKE TRUCK TO PULL ELECTRIC TRAILER Section L-5 Controls TA900A Features Include: Time Actuated Power: Trailer brakes are gradually applied at pre-set rates. Full brake actuation in 2 seconds. 100% solid state. Manual Override: Aids in setting controls and allows manual brake actuation, activates brake lights. Multi-color LED: Indicates completed circuit, brake actuation and brake wire shorts. Installation: Mounts in any position, no leveling required, quick disconnects for easy removal. Warranty: Limited lifetime warranty. PART NO. REF.NO. DESCRIPTION TA900A ELECTRONIC BRAKE CONTROL FOR 1-3 AXLES TA1000 Features Include: Time Actuated Power: Trailer brakes are gradually applied at pre-set rates. Full brake actuation in about 2.5 seconds. 100% solid state. Manual Override: Aids in setting controls and allows manual brake actuation. Two Color LED: Indicates completed circuit and brake actuation. Installation: Mounts in any position, no leveling required. Warranty: Limited 5 year warranty. PART NO. REF.NO. DESCRIPTION TA ELECTRONIC BRAKE CONTROL FOR 1-2 AXLES Section L-6 TA1200 Features Include: Digital Display: Displays voltage being applied to brakes; presence of short circuit and trailer connection. Time Actuated Power: Trailer brakes are gradually applied at pre-set rates. Full brake actuation in about 2.5 seconds. 100% solid state. Manual Override: Aids in setting controls and allows manual brake actuation. Installation: Mounts in any position, no leveling required. Digital readout can be reset for installation requiring upside down mounting. Warranty: Limited lifetime warranty. PART NO. REF.NO. DESCRIPTION TA DIGITAL BRAKE CONTROL FOR 1-3 AXLES Control Installation Kits All in one package - Everything needed for proper brake control in stal la tion! Redline offers a universal kit, including all wire and electrical items nec es sary for a standard brake control installation. Vehicle specific kits plug directly into the vehicle wiring harness. TA Universal Kit TA TA TA TA UNIVERSAL BRK CNTRL KIT, INCLUDES WIRE, TERMINALS & BREAKER TA BRK CNTRL HARNESS W/PRODIGY-P RIMUS ADAPTER FOR GM TRUCKS W/TOWING PKG TA BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR GM TRUCKS W/TOWING PKG TA BRK CNTRL HARNESS FOR GM TRUCK TA BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR FORD, F150 ONLY TA BRK CNTRL HARNESS FOR FORD TRUCK, F150 ONLY TA BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR FORD SUPER DUTY TA BRK CNTRL HARNESS FORD SUPER DUTY TRUCK TA BRK CNTRL HARNESS FORD F150 W/CNTLR CTR TA BRK CNTRL HARNESS W/PRODIGY-PRIMUS ADAPTER FOR DODGE RAM P/U & DURANGO TA BRK CNTRL HARNESS FOR DODGE TRUCK TA BRK CNTRL HARNESS 2010 DODGE RAM W/CNCTR TA BRK CNTRL HARNESS, HONDA TRUCKS W/PRODIGY TA BRK CNTRL HARNESS, NISSAN TRUCKS W/PRODIGY TA BRK CNTRL HARNESS, TOYOTA TRUCKS W/PRODIGY Section L-7 Control Accessories 2180S PULSE PREVENTER PREVENTS INTERFERENCE BETWEEN 4-WAY FLASHER & BRAKE CONTROL TEKONSHA TRAILER EMULATOR, 7-WAY RV TYPE CONNECTOR Side-Post Mount Battery Adapter Kit Allows direct connection to battery on vehicles using a side-post battery. TA SIDE POST MNT BATTERY ADAPTER KIT, CONTAINS ADAPTERS, NUTS & CONNECTORS (QTY 2) The Engager Breakaway Kits Easy to monitor battery condition. A simple push to test button on the front activates LED lights. A weld-on mounting bracket is also available. BA BA Section L-8 BATTERY APPLICATION BA ENGAGER BRKWY KIT, W/LED CHARGE INDICATOR 5AMP/HR 1-2 AXLES BA ENGAGER BRKWY KIT, FLIP-TOP W/LED INDICATOR 5AMP/HR 1-2 AXLES BA10-150BKT WELD-ON BRACKET W/STUDS, FITS BA REPLACEMENT PIN & CABLE FOR ENGAGER SWITCH Breakaway Kits These Electronic Breakaway Kits feature a re charge able, sealed, maintenance-free battery and an op tion al charger, for trouble-free towing. (Choice of 4 Battery Box Designs.) Compact Design Rechargeable, sealed, main te nance-free 12v Battery Dependable Wide operating tem per a ture (-76ºF to +140ºF) Meets or exceeds D.O.T regulations BA D2903K Breakaway Kits BATTERY BATTERY SWITCH CHARGER APPLICATION BOX BA REDLINE, W/CHRGR 5 AMP/HR BA YES 1-2 AXLES FRONT LOAD BRKY KIT W/CHGR, LED INDCTR NONE BA YES 1-2 AXLES TOP LOAD 42905K BRKY KIT W/CHGR, LED INDCTR 5 AMP/HR BA YES 1-2 AXLES TOP LOAD BRKY KIT W/CHGR, LED INDCTR NONE BA YES 1-2 AXLES FRONT LOAD 42906K BRKY KIT W/CHGR, LED INDCTR 5 AMP/HR BA YES 1-2 AXLES FRONT LOAD D BRKY KIT W/CHG NONE BA YES 1-2 AXLES FRONT LOAD D2903K BREAKAWAY KIT 5 AMP/HR BA YES 1-2 AXLES FRONT LOAD D BREAKAWAY KIT NONE BA NO 1-2 AXLES FRONT LOAD D2904K BREAKAWAY KIT 5 AMP/HR BA YES 1-2 AXLES FRONT LOAD BKW BRKY KIT, PREWIRED QTY 10 5 AMP/HR BA YES 1-2 AXLES FRONT LOAD BKW BRKY KIT, PREWIRED QTY 10 5 AMP/HR BA NO 1-2 AXLES FRONT LOAD TEKONSHA, NO CHRGR 4 AMP/HR 2005 N/A 1-2 AXLES A TEKONSHA, W/CHRGR 4 AMP/HR AXLES TEKONSHA, NO CHRGR 5 AMP/HR 2010 N/A 1-3 AXLES TEKONSHA, W/CHRGR 5 AMP/HR AXLES TEKONSHA, NO CHRGR 5 AMP/HR 2010 N/A 1-3 AXLES TEKONSHA, W/CHRGR 5 AMP/HR AXLES TEKONSHA, NO CHRGR 5 AMP/HR 2010 N/A 1-3 AXLES TEKONSHA, W/CHRGR 5 AMP/HR AXLES See next page for Breakaway Kit Accessories. Section L-9 Breakaway Kit Accessories PIECE BA UB1250 BA BA Section L-10 BA REDLINE BATTERY, 12V, 5AMP BATTERY SEALED, CLAM-PKGD BA REDLINE BATTERY, 12V, 5AMP/HR FOR 1-2 AXLE TRAILERS UB SEALED LEAD ACID BATTERY, 12V, 5 AMP/HR FOR 1-2 AXLE TRAILERS BA NYLON BRKY SWITCH W/METAL BRACKET, PKGD BA V MAINTENANCE CHARGER FOR BRKY KITS, PKGD LED BREAKAWAY SWITCH, 7 WIRES REPL PIN & CABLE FOR BREAKAWAY SWTCH 20010H BRKY SWITCH, HOPKINS NEW STYLE, 7 WIRES 2005A REPL PIN & CABLE, FITS 2005 BREAKAWAY SWITCH BRKY SWITCH, ALL METAL W/SILVER CONTACT POINTS & BRASS PULL PIN BRKY SWITCH, NYLON CASE, WELDABLE METAL TAB, SILVER CONTACT POINTS, NYLON PULL PIN 2010A REPL NYLON PULL PIN & CABLE FOR 2010 BRKY SWITCH BATTERY CASE, POLYETHYLENE PLASTIC, A-FRAME OR JACK POST MOUNT BATTERY CASE, POLYETHYLENE PLASTIC, LOCKABLE, FLAT SURFACE MOUNT, WELD-ON BATTERY CASE, POLYETHYLENE PLASTIC, LOCKABLE, FLAT SURFACE MOUNT, BOLT-ON MAINTENENCE BATTERY CHARGER, 12V (WILL NOT FULLY RECHARGE BATTERY) QUICK BATTERY RECHARGER, 12V (WILL RECHARGE BATTERY IN APPROX. 4-5 HRS) Carlisle Hydrastar Electric-Hydraulic Actuators HYDRASTAR FEATURES: 12V DC powered electric-hydraulic pump-style actuator for electronically controlled hydraulic brakes Compatible with most industry standard electronic brake controllers. (Use HBA-CAM for controller compatibility issues.) Unloading Piston feature instantly releases hydraulic pressure upon stop of brake signal, eliminates pump-style actuator brake drag. Completely sealed to be a weather-tight unit, approved for marine applications Actuator designed for single or tandem axle applications Compact design, measures 3.25 W x 5.75 H x 17.5 L For use with industry standard 5 AMP/HOUR Breakaway Kit 2-Year Warranty Part No. Ref. No. Description HBA-CAM CONTROL ADAPTER MODULE HBA PSI UNIT CAR-HBA10-2A PSI DRUM TDM W/9505 LINE KIT & BRKY CAR-HBA PSI DRUM TDM W/DELX LINE KIT & BRKY HBA PSI UNIT CAR-HBA PSI DISC TDM W/DELX LINE KIT & BRKY (3.5k-8k) CAR-HBA16-2HD PSI DISC TDM W/10-12K LINE KIT & BRKY HBA-BKT BOLT-ON MOUNTING BRACKET FOR HYDRASTAR HBA-BC REP L FILLER CAP, HBA-SERIES HYDRASTAR What s stopping your trailer? Carlisle Hydrastar XL Electric-Hydraulic Actuator HYDRASTAR XL FEATURES: HBA-CAM Controller Adapter Module: Makes the HydraStar unit compatible with most Ford OE Tow Command controllers (where needed), & GM Factory Controllers. Easy to install, simply splice in four wires & mount the module where convenient. Check with your Redneck Customer Service Team for current applications. The Carlisle Hydrastar XL uses an on-board microprocessor and accelerometer to sense the amount of braking effort being generated by the tow vehicle. The Hydrastar XL does not require a hard-wired in cab electronic brake controller. The hand held actuator plugs into the cigarette lighter, using the vehicle s original wiring to transmit signals to the actuator. The Hydrastar XL is great for any situation where multiple tow vehicles may be used to pull a single trailer, especially rental units. No hard-wired brake controller necessary. 17 Amp/Hour break-away battery kit required No special wiring needed, no compatibility conflicts w/factory vehicle controllers. Great for rental units or where using multiple tow vehicles on a single trailer. Part No. Ref. No. Description HBAC10-CLR XL, 1000 PSI UNIT W/IN-CAB CONTROLLER CAR-HXL10-2A XL 1000PSI KIT W/CNTRL, HYD LINE & BRKY CAR-HXL XL 1000PSI KIT W/CNTRL, DLX LINE KIT & BRKY HBA-EBA AMP BREAKAWAY KIT FOR HYDRASTAR XL/ELECTRASTAR Hydrastar XL with controller Section L-11 Hydraulic Actuators Master cylinder cap has a diaphragm providing a completely enclosed hydraulic brake system on all models. Raised fill plate prevents contaminants from entering master cylinder when removing cap on all models. Tie loops on cap can be used for a tamper resistant seal. Bellow boot on push rod for moisture and dirt prevention on all models. Emergency lever guide with color coded decal indicates if brakes are on or off (all models EXCEPT DA66B). line pressure controlled by spring loaded push rod assembly. Integrated shock dampening design. Emergency brake-away lever with cable hook-up and easy reset. Corrosion resistant finish provides long-lasting, attractive appearance. Plated finish is 500 hour salt spray tested. 6,000 lb. to 20,000 lb. actuators utilize acetal copolymer linings. Rollers are eliminated on DA91, DA10 and DA20 models. Composite, Corrosion-Free Master Cylinder! DA9150-2HBC Section L-12 Actuators* 6K ACTUATOR DA66B ZINC, 3 TONGUE, 2 COUPLER, DRUM DA66B ZINC, 3 TONGUE, 2 COUPLER, DISC 8K ACTUATOR PART REF DA91 W/CHANNEL ONLY, 3 TONGUE, DRUM DA91-2HBC DA91 W/ADJ 2 H-BLOW COUPLER (7,000 LB.), DRUM DA HBC DA91 W/ADJ 2-5/16 H-BLOW COUPLER, DRUM DA9150 W/CHANNEL ONLY, A-FRAME, DRUM DA9150-2HBC DA9150 W/ADJ 2 H-BLOW COUPLER (7,000 LB.), DRUM DA HBC DA9150 W/ADJ 2-5/16 H-BLOW COUPLER, DRUM 12.5K ACTUATOR PART REF DA10 W/FIXED 2-5/16 COUPLER, DRUM DA10 ZINC, 2 5/16 DROP COUPLER, DRUM DA10 ZINC, 2 5/16 DROP COUPLER, DISC DA10 W/CHANNEL ONLY, DRUM DA10-3ADJEYE DA10 W/3 ADJ EYE, DRUM DA ADJ-HBC DA10 W/ADJ 2-5/16 H-BLOW COUPLER, DRUM DA ADJ-ATW DA10 W/ADJ 2-5/16 ATWOOD COUPLER, DRUM 16K ACTUATOR PART REF DA16 ZINC, 2 5/16 DROP COUPLER, DISC 20K ACTUATOR PART REF DA20 ZINC, 2 5/16 DROP COUPLER, DRUM DA20 ZINC, 2 5/16 DROP COUPLER, DISC DA20 W/CHANNEL ONLY DA ADJ-ATW DA20 W/15K, ADJ 2-5/16 ATWOOD CPLR DA20-3ADJEYE DA20 W/3 ADJ EYE Demco Actuator Replacement Parts MASTER CYL, DRUM, FITS ALL MODELS MASTER CYL, DISC, FITS ALL MODELS MASTER CYL CAP, FITS ALL MODELS SHOCK, FITS DA66 ACTUATORS DS SHOCK, FITS DA91, DA10 & DA20 ACTUATORS BRKWY CABLE/LEVER FITS DA91, DA10, DA20 DO BRKWY CABLE/LEVER KIT FITS DA66 ACTUATORS *Disc Actuators feature back-up solenoid pre-installed. Section L-13 Titan Actuators Model 10 Model 60 Leverlock Drum Section L-14 Model 20 Model 60 Leverlock Disc MODEL 60, 6K ZINC, 1-7/8 or 2 ADJ LVRLOCK CPLR, DRUM MODEL 60, 6K ZINC, 1-7/8 or 2 ADJ LVRLOCK CPLR, DISC MODEL 10, 12.5K ZINC, 2-5/16 DROP CPLR, DRUM MODEL 10, 12.5K ZINC, 2-5/16 DROP CPLR, DISC MODEL 20, 20K ZINC, 2-5/16 DROP CPLR, DRUM MODEL 20, 20K ZINC, 2-5/16 DROP CPLR, DISC MASTER CYLINDER, DRUM, MODEL MASTER CYLINDER, DISC, MODEL M-CYL CAP & GASKET, MODEL SHOCK, MODEL COUPLER REPAIR KIT, MODEL 60, MULTIFIT CPLR COUPLER REPAIR KIT, MODEL 60, LEVERLOCK CPLR M-CYL COVER-GASKET, MODEL MASTER CYL COVER, MODEL 60, USE W/ MASTER CYLINDER, DRUM, MODEL 10 & MASTER CYLINDER, DISC, MODEL 10 & HYD CONN FITTING, MODEL 10&20 OLD STYLE M-CYL CAP, MODEL 10 & 20 DS SHOCK, MODEL SHOCK, MODEL 20 NOTE: Disc Actuators feature back-up solenoid pre-installed. Atwood Actuators Atwood Actuators have heavy gauge stamped steel housings, with ball socket as sem blies. Breakaway mechanism sets and locks the trailer brakes in the event of tow vehicle/trailer separation.
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