OWNERS MANUAL AND INSTALLATION INSTRUCTIONS

1 OWNERSMANUALANDINSTALLATIONINSTRUCTIONSA ctive Technology7600 Sand Drive Fort Worth, Texas OFCONTENTSPage OneActiBrake - part of a SystemModel Numbers, Brake Controllers and Wire ConnectionsPage Two8 Major Steps of Installing ActiBrakePage ThreeMounting the ActiBrake UnitPage FourInstalling the Hydraulic LinesFilling the ReservoirPage FiveProper Wire ConnectorsElectrical System TestsPage SixElectric INSTALLATION and Electrical ConnectionsActiBrake Wiring InstallationPage SevenActiBrake Wiring InstallationBreakaway ProtectionPage EightBreakaway Battery Surge ProtectionBleeding the Brake LinesPage NineGeneral OperationCouplingTrailer Connector - Vehicle ConnectorPage TenBecoming Familiar with Braking of the Coupled Tow Vehicle - TrailerBrake Controller Signal Determines Trailer Brake PressureWhich In-Cab Controller is Best?Page ElevenSettings and Use of In-Cab ControllersDo Not Ride Your Brake PedalExtend A LifeReplacement PartsPage Twelve Service and MaintenancePage ThirteenTrouble ShootingPage FourteenTrouble Shooting (continued)Page FifteenWarranty- In-cab brake controller- A reliable, fully charged 12 volt breakaway battery- Breakaway switch- 7-way trailer connector - wiring harness paired with a matching tow vehicle connector, properly wired to the tow vehicle- A reliable, fully charged 12 volt battery in your tow vehicle- Properly rated wires and wire connectors- The proper size hydraulic lines free from obstructions, kinks or pinch-points- Quality hydraulic disc or drum trailer brakesActiBrake - part of a SystemActiBrake is part of a trailer braking system.

2 For this system to be complete, you alsoneed the following components:You Should ControllersYour trailer braking system is like a chain. It is only as good as its weakest link. This is especially true regarding in-cabbrake controllers. There are many marginal brake controllers on the market, and ActiBrake will only apply the level ofbraking indicated by the brake controller's "blue wire" signal. Therefore, we urge you not to economize on a brakecontroller because it will only diminish the overall performance of ActiBrake and your trailer braking system in general. Seepage 10 for a list of approved brake controllers. Important:Unlike electric drum brakes, the ActiBrake does not receiveits powerthrough the blue wire . The power to the ActiBrake is provided through a +12 volt (normally black) wire from thetow vehicle connectionsA common cause for trailer brake system problems is improper wire connections. You must use the properly rated wireconnectors (such as the crimp-type, heat shrink connectors enclosed in the ActiBrake shipping box, or any high quality,sealed connector) or sealed solder connection to ensure a reliable and lasting wire connection.

3 Never use twist typeconnectors, tap splice connectors, electrical tape over a twisted connection or other such methods as they will eventuallyfail and create a wide array of operational problems. See page 6 for more information about proper wire 1 ActiBrake is available in three models:Drum Brake- for hydraulic 10 & 12 inch drum brakes(model # AB-1-8)Disc Brake- for hydraulic disc brakes up to and including 8,000 lb. axles(model # AB-1-14)Heavy Duty- for all hydraulic brakes on 10,000 lb. axles and above(model # AB-1-16HD)ActiBrake was designed, manufactured and tested to meet the J1455 SAE standard with the goal of creating the most robust, reliable trailerbrake actuator available. Page 2 Installing and Testing ActiBrakeStep #1 Mounting the ActiBrake on the #2 Installing the hydraulic brake lines on the #3 Connecting the hydraulic brake line to the ActiBrake and filling the #4 Electrical INSTALLATION of the ActiBrakeStep #5 Checking the breakaway #6 Bleeding the brake #7 Complete system test to ensure everything is functioning #8 Setting the in-cab controller to establish the correct level of trailer OWNERS MANUAL and INSTALLATION Instruction outline the correct proceduresfor conducting each of the 8 steps listed !

4 Follow these INSTRUCTIONS carefully when installing and using the are 8 Major StepsPage 3 Mounting the ActiBrake to the TrailerThe ActiBrake unit must be mounted upright in a location you desire, with consideration for accessibilityfor service, brake line and wiring INSTALLATION and protection of the unit from damage. The unit should bemounted close to the front of the trailer to reduce the effect of voltage drop through long spans of wireand junction boxes. SEE THE TABLE BELOW for more information on voltage drop. The ActiBrake should be mounted using 2 mounting straps (sold separately) which fit over the rubber-lined mounting strap slots on the unit. There are two types of straps; top mount or side mount. Four5/16-18 bolts (not included) are placed through the holes in the feet of each mounting strap. The strapscan be bolted to any flat surface on the trailer or they can be mounted to a factory formed bracket (soldseparately).

5 This bracket may be bolted or welded to any suitable surface (either horizontally orvertically) and thereby form the base of the mounting You Mount the ActiBrake!Ensure the selected location is accessible for service and for brake line and wiringinstallation. The ActiBrake is sealed and designed to be water-tight to a depth of 1 footfor up to 5 minutes per submersion occurrence. However, it is best to mount the unit in alocation in which it will not be submerged or that will reduce the risk of Drop Over DistanceVoltage Drop Calculation: Wire length x resistance x pump current = voltage drop*Resistance 50 feet, the voltage drop on 10ga wire would be approximately 5V at 25 amps. (50 x .0037 x 25) = *This does not include connectors ( ohm), splices (welded ohms), or any other device in thecircuit path such as fuses and mount strapside mount strapmounting bracketPage 4 Filling ReservoirAfter all brake lines have been installed, connected, and properly tightened, fill the reservoir with NEW,CLEAN, "DOT 3" or "DOT 4"Brake Fluid.

6 Never re-use brake fluid that has been salvaged orremoved from another unit. Contaminated or dirty fluid can cause system failure and/or prematurewear on the system components. DO NOT OVER FILLthe reservoir. The fluid level should beapproximately 3/4 inch from the top of the filler only new, clean, DOT 3 or DOT 4 brake fluid from a sealed container. Donot fill with previously used fluid. Used fluid may absorb water or otherimpurities which may cause corrosion and/or poor brake performance. Thismay result in physical injury and/or property damage!Warning!Failure to follow these INSTRUCTIONS may cause the system to malfunction,which may result in physical injury and/or property damage, and may causeirreparable damage to the ActiBrake, which will void the ! INSTALLATION of Hydraulic LinesThe ActiBrake unit has a brass 1/8th NPTF male fitting with #3 (3/16) female inverted flare tube seatadapter,*(for 1/8 brake line).

7 DO NOT use Teflon pipe tape or other type of thread dope whenconnecting brake tubing or hose. When installing steel tubing, use care to avoid sharp kinks orbends, which can restrict brake fluid flow causing poor brake response. Double flarethe ends of thesteel tubing to ensure tight leak proof connections. All steel hydraulic lines should be anchored at twofoot intervals to prevent vibration and chafing. Rubber hydraulic hose should be used at points whereflexing may occur. Be sure hydraulic hose is positioned so it does not rub against any surface duringtrailering. Anchor ends of tubing to minimize stress.* Model AB-1-16-HD utilizes a brass 1/8 NPTF male fitting with #4 (1/4 ) female inverted flare tube seat adapter, (for 3/16 brake line).Page 5 Proper Wire ConnectorsThese crimp-type, heat shrinkconnectors are enclosed in yourActiBrake shipping Gauge(yellow)16 Gauge (blue)This is theRightway of making wire is theWrong way of making wire type connectors mayvibrate loose which will createa short in the wiring just electrical tape isnot sufficient.

8 The wires maybecome corroded or vibrateloose creating a shortcuts when connecting any wireson your trailer only increases the likelihoodthat some part of your electrical system willfail. Whatever type of connector you decideto use, make sure it is durable and is sealedagainst exposure to water and Loose or Poorly JoinedWire Can Disable Your EntireBrake SystemUse a standard crimp tool to crimp the wires in the connector, then usea heat gun to shrink the plastic ends of the connector to seal INSTALLATION and System TestsIf you are installing the ActiBrake, carefully follow the INSTALLATION and test procedures outlinedin this is essential that you follow all set-up, wiring and test procedures to ensure thatyour ActiBrake is properly installed and tested. Failure to follow these proceduresmay damage the ActiBrake, and may result in physical injury and/or propertydamage. Warning!Important!The Number One INSTALLATION Problem is Improper Wiring of the Set-up, wiring, testing procedures outlined in the following pages of this not connect these wires by color but by function!

9 Failure tofollow these INSTRUCTIONS may damage the ActiBrake unit and will void Wires and Wire ConnectionsThe wires on the ActiBrake system wiring harness are approximately 18 inches longto allow forflexibility when mounting the unit, however, extensions may be required to connect unit to thetrailer's electrical wiring. When making connections to the trailer's wiring harness, the desiredtermination is a solder joint. If the connection is not soldered, use the appropriate size and typeof "crimp-type" heat-shrink connector, using the manufacturer s recommended crimping tools inaccordance with their crimping INSTRUCTIONS . It is EXTREMELY IMPORTANTto connect the wiresfrom the ActiBrake to the appropriate wire in the trailer's wiring harness, which correspondsprecisely with their designated function. Page 6 Warning!NOTE:Unlike electric drum brakes, the ActiBrake requires +12 volts from the tow vehiclethrough the tow vehicle s connector (normally black wire).

10 The ActiBrake will not function properlywithout this +12 volt source. A 30 amp blade type fuse is included in the 12 volt supply wire onthe ActiBrake wiring harness (available at most automotive supply stores). This fuse protectsagainst possible damage caused by mistakenly wiring the ActiBrake with reversed Wiring InstallationIt is very important to exactly follow these wiring INSTRUCTIONS :Step 1:a) Ensure that the white wire on the ActiBrake is connected to bare metal on thetrailer ) Ensure that the white wire from the ActiBrake is connected to the negativeterminal of the breakaway ) Finally, connect the white wire of the ActiBrake to the (normally white) towvehicle battery ground wire (via the trailer connector). All three ground connectionsare essential for the ActiBrake to function : The ground wire from the in-cab controller must be connected to the samegrounding point used for the tow vehicle battery ground the harnessconnector using a 1/4 socket.