CURT Triflex Brake Controller Installation Guide
- June 9, 2024
- Curt
Table of Contents
Trifled Brake Controller
Installation Guide
TRIFLEX™ BRAKE CONTROLLER
INSTALLATION AND USER GUIDE
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
This package includes:
(1) Brake control module with quick plug
(1) Mounting bracket
(6) Mounting bracket screws
(1) Quick reference card
One or more of the following may be needed to complete installation:
- Brake control connection harness, supplied with the tow vehicle (if equipped)
- If your vehicle does not have a factory installed quick plug, you will need to run wires to the brake controller using the supplied connector and terminals
Important Information
Read and follow installation and setup instructions carefully. Failure to do
so could result in damage to the brake control unit, no trailer brakes or poor
brake performance.
Disconnect the electrical plug between the trailer and tow vehicle before
testing a breakaway switch. Failure to disconnect may damage the brake control
unit.
Avoid mounting the brake control module near a CB radio or other RF
transmitter.
WARNING: The brake control unit must be mounted firmly in place.
Failure to do so could lead to improper operation and/or brake failure.
WARNING: The brake control unit’s positive (with 30 amp circuit breaker)
and ground wires must be connected directly to the tow vehicle’s battery using
10 gauge minimum stranded wire. Connecting to existing wiring or an alternate
ground may damage vehicle circuits, lead to failure of the brake control
module, loss of trailer brakes or vehicle fire.
NOTICE: Removal of the factory supplied quick plug can void warranty.
Key Features
- Digital display provides detailed brake force output and sensitivity position
- Provides automatic and manual trailer braking
- Switchable manual control output, 100% or limited to output setting
- Switchable manual control brake light activation or no brake light activation
- Compatible with electronic systems (anti-lock brakes and cruise control)
- Protected against reverse voltage, voltage spikes, shorts and overloads
- Power conservation mode after 30 min. of inactivity, wakes when brake pedal is pushed
- Display is capable of communicating operational errors
- Reduced output when sitting still (railroad crossing, stoplight, etc…)
- Automatically compensates for uphill and downhill road conditions
- Will work with most electrically activated hydraulic trailer brake systems
Controls and Components
- Digital display
- Sensitivity adjustment
- Output adjustment thumb wheel
- Manual control lever
- Quick plug connector
- Switch for manual control max output, 100% or output setting
- Switch for manual control stoplight activation
- Mounting bracket
CONTROLS AND DISPLAY
Output Control
The output control thumbwheel establishes the maximum amount of power
available to the trailer brakes when braking. The only exception would be when
the manual control is setup for 100% braking, see ‘Set Manual Control Output
and Brake Light Switches’.
As the output control is rotated, a flashing display shows the setting. When
turned to the right, more power will be available to the brakes; when turned
to the left, less power will be available. Display flashes the setting for a
few seconds after adjustment is complete. The output control would be adjusted
during initial setup, when trailer load changes, when different trailers are
used or when adjustment is needed for changing road or driving conditions.
The maximum output setting is shown on the display when a trailer is connected
and the brake pedal is pressed or the manual control is actuated. If a trailer
is not connected the output setting is flashed when the brake pedal is
pressed or the manual control is actuated. The output setting is shown as
through .
Sensitivity Control
The sensitivity control adjusts trailer brake aggressiveness. The trailer
brakes become more aggressive as the switch is moved toward the driver. To
view sensitivity setting on the display, move control slightly, the setting
will flash.
Sensitivity adjustment has no effect on the manual control. The sensitivity
control would be adjusted for individual driver preference, trailer load
changes or changing road conditions. The sensitivity control setting is shown
as through with being the least aggressive and being the most aggressive.
The display flashes the setting for a few seconds after adjustment is
complete.
**Manual Control
**
The manual control is located on the front of the brake control unit at the
left side and only applies trailer brakes. Manual brake control activation is
used during initial setup and in situations where a slow reduction in speed
is desirable. As the manual control is pushed to the right, the brake control
begins to apply the trailer brakes.
The further to the right it is pushed the harder the brakes are applied.
The manual control can be setup to either allow 100% of the unit’s power to
the trailer brakes or to limit power to the output control setting. This
feature is setup at installation via a small switch at the rear of the unit.
See ‘Set Manual Control Output and Brake Light Switches’. The brake control
unit is shipped from the factory with the switch in the ‘limited to the
output control’ setting position.
The output will be shown on the display when the manual control is actuated.
Brake light activation with the manual control is also an optional setting.
Some tow vehicle’s circuits do not allow power for brake lights from a second
source.
In these applications, the brake light feature can be switched off using a
second small switch at the rear of the unit. The brake light connection (red
wire) is still required to activate the TriFlex brake control with the switch
in either position.
See ‘Set Manual Control Output and Brake Light Switches’. The brake control
unit is shipped from the factory with the switch in the ‘activate brake light’
position.
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.
| Blank display, does not illuminate when control is activated, check
installation| | Flashing, trailer disconnected, off after 60 seconds
---|---|---|---
| Blank display, standby mode, illuminates when control is activated| |
Recalibration needed, unplug and replug trailer connector
| Standby mode, no trailer connected| | Calibrating
| Standby mode, trailer connected| | Overloaded output circuit, trailer brake
system fault
| Brakes activated| | Low voltage, tow vehicle system
| Flashing, output adjustment mode| | Accelerometer error, powers brakes using
default values
| Flashing, sensitivity adjustment mode| | Stoplight wire (red) shorted to
ground
| Trailer connected, checking calibration| | Battery power just connected or
engine cranking
INSTALLATION
Set Manual Control Output and Brake Light Switches
There are two small switches located at the rear of the unit that can be
accessed by removing the rectangular cover. Once accessed, the switch
positions can be changed using a small pointed tool.
In the illustration above, the switch on the left (#1) controls the unit’s
brake light activation feature. The factory default setting is the ‘ON’
position with the switch down. This setting activates the tow vehicle and
trailer brake lights when the manual control is actuated. Moving the switch up
to the ‘OFF’ position turns off the brake light activation feature and the
brake lights are not activated when the manual control is actuated.
In the illustration above, the switch on the right (#2) controls the level of
output available to the trailer brakes when using the manual control. The
factory default setting is the ‘ON’ position with the switch down. This
setting limits the manual control output to the level set using the output
control thumb wheel. Moving this switch up to the ‘OFF’ position allows 100%
of the output to the brakes when the manual control is actuated regardless of
the output control setting.
The brake light connection (red wire) is still required to activate the TriFlex™ brake controller with the switch in either position. Be sure to check with your local regulations and ensure you are in compliance.
Mounting
-
Determine a suitable mounting location.
A) The unit must be mounted securely to a solid surface
B) The unit must be easily reached by the driver
C) The area behind mounting location must be clear so no damage will be done when drilling -
Hold the mounting bracket in the selected position and mark the hole locations through the bracket.
-
Using a 1/8″ diameter bit, drill holes in the marked locations.
-
With a screwdriver or a 1/4″ nut driver, secure the bracket in place using (2) self threading screws (provided). Do not over-tighten.
-
Mount the brake control unit in the bracket using (4) screws.
Wiring
Disconnect the tow vehicle’s negative battery terminal from its battery post
before beginning the wiring process.
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.
Mount a 30 amp, auto reset, circuit breaker as close to the battery as
possible.
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.
WIRING DIAGRAM
Feed two 10 gauge wires, one white and 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 to be
connected 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. Again 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
NOTE: Stoplight switch connection on Ford vehicles including, Mercury
Mountaineer.
Do not connect to the red wire with a green stripe. Connect to the light green
wire only.
For vehicles other than 1989-1991 Ford E and F Series trucks and vans with
anti-lock brakes, use a test probe, determine which wire on the tow vehicle’s
stoplight switch is only “hot” when the pedal is pressed. Splice the brake
control’s red wire to this wire using a wire tap.
For 1989-1991 Ford E and F Series trucks and vans with anti-lock brakes: Find
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 of seven wires (see the box shown in wiring the
diagram). Splice the brake control brake control’s red wire to light green
wire using a wire tap.
Using 10 gauge stranded wire and ring terminals, connect the BATT” side of the
circuit breaker to the positive battery terminal.
Attach the white 10 gauge wire previously positioned near the battery to the
negative battery terminal using a ring terminal. Reconnect the tow vehicle’s
negative battery terminal to its battery post. See vehicle’s owner’s manual
for special battery re-connection instructions.
Test the installation without a trailer connected, by pushing the brake pedal. A single decimal point should light up on the display. If the decimal point does not light, or if , or is shown refer to display messages. After testing secure all loose wires with cable ties so that they will not be damaged.
SETUP
Once all electrical connections are complete and the single decimal point is
seen, while parked on a level surface, plug the trailer’s electrical connector
into the tow vehicle’s plug.
Making the trailer connection initiates the mounting position calibration
mode.
may be seen on the display followed by either or . If appears , recalibration
is needed. To recalibrate, unplug and replug the trailer’s electrical
connector. While calibrating, the display will show or may flash the Output
setting. When appears, the unit is calibrated and ready for setup.
Make the following preliminary adjustments with the trailer connected and
engine running to ensure proper charge voltage. The vehicle must be in park or
neutral with the parking brake applied, foot off the brake pedal, and no
manual control actuation:
Adjust output to by turning the output control wheel left or right as needed.
Adjust sensitivity to by moving the sensitivity control forward or back.
Test Drive and Adjustment
Both output and sensitivity can be adjusted to achieve smooth firm stops.
Output and sensitivity adjustments should only be made while stopped, with the
transmission in park or neutral, parking brake applied, foot off the brake
pedal, and no manual control actuation. Output and sensitivity settings will
flash while adjustments are made and for a few seconds after.
Start with the output adjustment. Drive forward on a paved or concrete surface
that is dry and level. At approximately 25 mph, apply the tow vehicle brakes.
If trailer braking is insufficient, adjust the output control to the right.
If the trailer brakes lockup adjust the output control to the left. Repeat
this step until stops are firm, just short of lockup.
Once the output is set, adjust sensitivity. Drive forward to approximately 25
mph and press the brake pedal. Tow vehicle and trailer should make smooth
stops. If the stops seems slow and more aggressive braking is desired, move
the sensitivity control toward the driver. If the stop seems too aggressive
adjust the sensitivity control away from the driver.
Make several stops at various speeds and adjust sensitivity until stops are
smooth and firm. Slight adjustment the output control may also be desirable.
NOTE: If any problems occur during setup, refer the trouble shooting
section.
HELPFUL TIPS
Light pressure on the manual control will activate the trailer’s brakes
with no effect on the vehicle’s brakes. This is useful for gradual slowing on
steep grades or before stops.
Periodic adjustment of the output and sensitivity controls may be necessary to
correct for changing road conditions, trailer loading, brake wear or driver
preference.
In some applications, when towing with hazard flashers on, the digital display
will flash with the hazard flashers. If the brake control is set aggressively
pulsing may be felt in the trailer brakes.
BENCH TEST INSTRUCTIONS
Parts Needed:
Standard 1156 automotive bulb in a socket, Charged 12V battery, Alligator clip
test leads OR wire and wire nuts, 51515 / 51516 Quick plug with pigtails OR
push pins NOTE: If a quick plug pigtail is not available push pins can be
used to make a direct connection to the female terminals of the Triplex quick
plug housing.
CAUTION: Ensure that the brake control wires, quick plug wires, push pins
and test leads do not make contact with each other or any other metal surface
–failure to do so may damage the brake controller.
Brake Controller Setup
Connect the quick plug to the Triplex to provide accessible wires for bench
testing.
Connect the white ground wire of the Triplex and the ground wire of the bulb
to the negative terminal of the 12V battery.
Leave the red brake input wire and blue output wire unconnected.
Connect the black battery wire of the Triplex to the positive terminal of the
12V battery.
If the brake controller is wired properly and the Triplex is operational the
display will flash the current sensitivity level (ex. ) followed by a single
decimal point .
Ensure the Triplex is level to the bench surface and connect the signal wire
of the bulb to the blue brake output wire of the Triplex.
The Triplex will display that it’s checking calibration , that it’s calibrating , or that it needs recalibration . If the indication appears, disconnect and reconnect the bulb from the blue wire to recalibrate. It will show when disconnected , and / or during calibration, followed by two decimal points when complete.
Manual Control Testing
Rotate the output control thumb wheel right to its maximum setting , move the
sensitivity adjustment toward the front of the unit to its most aggressive
setting , and slowly activate the manual control up to its full output.
While actuating the manual control the brightness of the bulb will correspond
with the output shown by the brake controller. Release the manual control to
deactivate.
Accelerometer Testing
While keeping the brake control level, connect the red brake input wire of the
Trifle to the positive terminal of the 12V battery. The brake control output
will activate and the bulb may be dimly lit.
Slowly tilt the front of the Triplex to about 45° and the brightness of the
bulb will increase corresponding with the output shown by the brake
controller. Slowly tilt the front of the Triplex back to level and the
brightness of the bulb will decrease corresponding with the output shown by
the brake controller.
When finished testing disconnect the wiring from the positive terminal of the
12V battery ensuring the exposed contacts to not make contact. If the TriFlex
does not function as described during the above test steps return the brake
controller for service or replacement.
BENCH TEST DIAGRAM
IMPORTANT: Read and follow all warnings and cautions shown on the battery
TROUBLE SHOOTING GUIDE – TEST WITHOUT TRAILER FIRST
No Trailer Connected
| Condition | Display | Probable Cause | Probable Solution |
|---|---|---|---|
| Decimal point does not light when brake pedal or manual control is used |
Blank
| No power to control, no ground, reversed black and white wires, circuit
breaker blown| Check and repair connections. Refer to the ‘wiring’ section
Decimal point on after 30 min of inactivity|
Decimal
| Red wire connected wrong side of the switch or to wrong to the stoplight
wire| Check and repair connections. to the ‘wiring’ Refer section
Display shows L.b Can also happen with
trailer connected| | Tow vehicle’s system voltage low| Check tow vehicle’s
battery and charging system
Display shows E.1. when manual control is applied| | Red wire connected to
ground side of stoplight switch or is shorted to ground| Check brake control
wiring, may require change to switch setting. See “manual control” section
Display shows OL when brake pedal or manual override is used|
Flashing
| Short in blue wire output circuit or trailer plug| Locate and correct short
Display shows — when battery power has not just been connected and the engine
is not being cranked|
Double dash
| Inadequate battery or ground wiring to brake controller| Check brake control wiring
With Trailer Connected
Condition|
Display
| Probable Cause| Probable Solution
---|---|---|---
Display shows only one decimal point hen power is applied to control. No
trailer brakes when brake pedal or manual control is used|
Decimal
| No connection between brake control and trailer brakes — blue wire circuit|
Confirm connection to trailer connector Confirm connector terminal positions
Check trailer
No trailer brakes, pedal or manual|
Output power not blinking
| MI’s-wired trailer connector| Confirm trailer connector terminal positions
No trailer brakes, pedal or manual|
Flashing
| Short or overload in trailer brakes| Troubleshoot trailer brake circuit per
brake
manufacturer’s instructions
Weak or no trailer brakes or trailer lights illuminate with brakes|
Output power
not blinking
| Misfired trailer| Check and correct trailer wiring
Trailer brakes on all the time|
Standby mode
Sleep mode
| MI’s-wired trailer connector| Check and correct connector wire positions
Display shows A.E. after releasing brake| | Internal error| Replace brake
control unit
No trailer brakes, pedal or manual|
Flashing
| Loss of trailer connection, unplugged or bad wiring| Stop and check trailer connector
AUSTRALIA WARRANTY POLICY
Australia’s Consumer Law
Our goods come with guarantees that cannot be excluded under Australian
consumer law. You are entitledr refund for a major failure and compensation
for any other reasonably foreseeable loss or damage. You are also entitled to
have the goods repaired or replaced if the goods fail to be of acceptable
quality and the failure does not amount to a major failure.
Product Warranty Coverage
CURT Products purchased from an authorized CURT dealer or retailer are
warranted to be free from defects in factory workmanship and materials for one
(1) year from the date of installation. The installation date will be
determined based on the invoice or receipt provided to you. This warranty
applies only to the original installation, and does not apply to any products
which are re-installed on a different vehicle. This warranty applies only to
products sold to retail purchasers in Australia and New Zealand, and different
warranty policies may apply to retail purchasers in other countries.
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from (1) normal use; (2) improper product selection, application or
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You must make a claim to receive any remedy under this warranty. To make a
claim or inquiry about this warranty, you should contact the dealer or
retailer you purchased the product from. You may also contact us at: CURT
Manufacturing, 6208 Industrial Drive, Eau Claire, Wisconsin USA 54702
+1-877-287-8634, 7am – 7pm (U.S.
Central Time) |
techsupport@curtgroup.com.au |
www.curtmfg.com.au
The remedies provided to you under this warranty are in addition to other
rights and remedies that may be available to you under Australian law. ****
References
Read User Manual Online (PDF format)
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