Draw-Tite BREAKAWAY SYSTEM W CHARGER User Manual

Technical Assistance Call Toll-Free: 1-888-785-5832 or www.tekonsha.com

ABCD/Tow Charger/12 Volt Lead-Acid Battery

Instructions and Installation

BREAKAWAY BATTERY CHARGER INSTALLATION

12 Volt Sealed Lead-Acid Battery

To maximize the life of the battery the following conditions should be met:

1. Avoid over or undercharge. This is the single worst enemy of lead-acid batteries.

2. Batteries should not be stored in a discharged state or at elevated ambient temperatures.

3. Avoid exposing batteries to heat! Service life is shortened considerably at ambient above 30°C (86°F).

4. Due to the characteristics of this battery, after six to nine months of storage, the battery should be recharged.

5. Charge the battery at the proper rate. Current should be limited to 1.2 amps or less.

6. Provide adequate air circulation when charging battery. Do not charge battery in any other container besides the supplied battery box.

7. CAUTION Do not place batteries in close proximity to objects which can produce sparks or flames.

8. Do not expose battery case to organic solvents or adhesives.

9. CAUTION Do not attempt to disassemble batteries. Contact with sulfuric acid may cause harm.

10. CAUTION Fasten batteries tightly and make provisions for shock absorption if exposure to shock or vibration is likely.

11. WARNING Do not throw batteries into fire; batteries so disposed may rupture or explode.

Battery Data Chart

• 12 VOLT

•4 amp/hr – max discharge current 20 hr. rate = 225 mA

•5 amp/hr – max discharge current 20 hr. rate = 250 mA

• Maximum Discharge Current = 40 amps

• Maximum charge current must be limited to 1.2 amps

• Length = 3.54” Width = 2.76” Height =

4.13” Weight = 3.8 lbs Terminals: Fasten Tab .187” x .032”

• Service Life: Under normal operating conditions, 4-5 years in standby applications or 200-1000 charge/discharge cycles depending upon depth of discharge and rate of charge.

1. Remove Charger and Battery from the battery case.

2. Mount battery case securely to frame, jack post or other suitable location on trailer.

3. Bolt Breakaway Switch

✼ to frame

of trailer or battery case bracket.

4. Install battery and charger into the battery case. Feed wires out the back, then close the top.

5. Wire per schematic diagram. Properly insulate all connections.

6. For Technical Assistance and Warranty Information call: 1-888-785-5832 or www.tekonsha.com

Important Facts to Remember

1. CAUTION Improper installation of the breakaway battery will destroy the brake control. The negative (-) terminal must attach to ground and positive (+) terminal must attach to the breakaway switch.

2. WARNING Check your Breakaway System✼ periodically to insure that wiring and connections are secure. A short or an open circuit can result in a no-brake condition.

3. If excessive discharging of the breakaway battery occurs, check battery and recharge using a Heavy Duty Two Stage /Maintenance Charger. If using a commercial (AC to DC) make certain the 12 volt charge is limited to 1.2 amps or less.

4. If the secondary battery needs charging, current will be drawn from the tow vehicle’s battery at anytime the tow vehicle is connected to the trailer. The most current which will be drawn is 1.2 amps.

To only charge the breakaway battery when vehicle is running, a battery isolator may be installed in the 12 volt supply line (BLACK wire for tow charger)

READ THIS FIRST:

Check condition of battery prior to installation and prior to each trip.

Tow

Charger

RED

BLACK

RED

BLACK

BLACK (+)

RED (+)

WHITE (–)

BLUE

WHITE

+12 Volt System

Stop Light Switch

+12 Volt System

Stop Light Switch

+12 Volt

Battery

+12 Volt

Battery

Automatic

Reset

Circuit

Breaker

Automatic

Reset

Circuit

Breaker

+12 Volt

Breakaway

Battery

+12 Volt

Breakaway

Battery

ABCD

RED

TOW VEHICLE

TRAILER

TOW VEHICLE

TRAILER

Breakaway

Switch

✼

Breakaway

Switch

✼

–

RED

–

+12 V

HEAVY DUTY QUICK/MAINTENANCE TWO STAGE CHARGER

ABCD (Accelerated Battery Charging Device)

–

Brake

Control

Brake

Control

TRAILER BRAKES

BLUE

✼ Refer to Breakaway Switch Installation Instructions for complete operating instructions and

cautionary statements.

TOW VEHICLE CHASSIS GROUND

P/N 2218 REV O 06/03

Installation Guide

1. Mount Battery Case securely to frame, jack post or other suitable location on trailer with Breakaway Switch Cable towards tow vehicle.

2. WARNING Switch location should be selected to ensure unobstructed line of pull in event of vehicle separation.

3. Bolt breakaway switch bracket to frame of trailer or battery case bracket using 1/4” bolt and lock nut or (2) 1/4” jam nuts. (Bolt and nuts not included in kit.)

4. WARNING Do not over tighten bolt. Switch must be able to pivot.

5. Check and install battery.

6. Wire per schematic. Properly insulate all connections.

7. Attaching to tow vehicle:Attach Breakaway Switch Cable to tow vehicle frame being certain the cable does not drag on the ground and no strain or restriction is placed on the cable.

8. WARNING Do not hook cable to safety chain loop or hitch ball.

Technical Assistance Call Toll-Free: 1-888-785-5832 or www.tekonsha.com

P/N 2218 REV O 06/03

ABCD/Tow Charger/ 12 Volt Lead-Acid Battery

Instructions and Installation

(Continued)

BREAKAWAY BATTERY CHARGER INSTALLATION

TOW VEHICLE

BREAKAWAY SWITCH

ELECTRICAL CONNECTOR

BATTERY

12 VOLT

SPLICE TO BRAKE OUTPUT FROM TRAILER BRAKES

BRAKE OUTPUT FROM BRAKE CONTROL

BLUE

BLACK

BRAKE OUTPUT FROM TRAILER BRAKES

TOW VEHICLE GROUND

GROUND

Important Facts to Remember

1. ATTENTION INSTALLER: Please give this sheet to consumer upon completion of installation.

2. SAFETY ITEM: Solder all wire connections.

3. Check condition of battery prior to each trip.

4. WARNING Disconnect trailer plug before testing breakaway unit. Failure to do so will result in severe damage to electronic brake control.

5. WARNING Check your breakaway system periodically to insure that wiring and connections are secure. A short or an open circuit can result in a no-brake condition.

6. For optimal performance, it is recommended that breakaway devices be replaced every 3-5 years.

For Technical Assistance and Warranty Information call: 1-888-785-5832 or www.tekonsha.com

READ THIS FIRST:

Read and follow all instructions carefully before installing or operating the Breakaway Switch. Keep these instructions for future reference.

BREAKAWAY SWITCH INSTALLATION INSTRUCTIONS