Prodigy Manual - The Expediter
Contents
1. Instructions for Electronic Brake Control For 2 4 6 and 8 brake applications READ THIS FIRST Read and follow all instructions carefully before installing or operating the Prodigy Keep these instructions with the Brake Control for future reference Components of the Brake Control A Power Knob B Boost Button C Manual Knob D Connector For Wiring Harness E Mounting Hole 1 per side Important Facts to Remember 1 Do not mount or activate RF generating items cell phones two way radios near less than 12 the brake control 2 Aa CAUTION Reversing the connection to a breakaway battery on the trailer will destroy the Prodigy 3 A CAUTION Disconnect trailer plug from the tow vehicle prior to testing a breakaway switch or you may destroy the Prodigy 4 The Prodigy employs an inertial sensor It senses deceleration and generates an output that is based on deceleration thus the term Proportional Braking 5 The Prodigy will HOLD your trailer with 25 of power setting while you are at a standstill with brake pedal applied for longer than 5 seconds 6 The Prodigy will brake proportionally in reverse It will apply the appropriate brake voltage based on deceleration 7 For Technical Assistance and Warranty Information call 1 888 785 5832 or www tekonsha com 8 44 WARNING The Gross Combined Weight Rating GCWR must never exceed the vehicle manufacturers recommendation 9 A CAU2. Leveling of the Sensor The Prodigy will automatically acquire the proper level setting It will also automatically adjust as you travel up or down hills Adjusting the Power to the Trailer Brakes Prior to setting Boost Once the control has been securely mounted within the 0 to 70 degree range it is necessary to set the power needed to stop the trailer during a braking event 1 Connect trailer to tow vehicle 2 With engine running hold manual full left and set Power Knob to indicate 6 0 9 Drive tow vehicle and trailer on a dry level paved surface at 25 mph and fully apply manual knob If trailer brakes lock up Turn power down using power knob If braking was not sufficient Turn power up using power knob ON ON gt Repeat Step 3 until power has been set to a point just below wheel lock up or at a sufficient force as to achieve maximum braking power 5 Using the brake pedal make a few low speed stops to check the power setting Trailer braking is initiated and terminated via the stoplight switch When the brake pedal is released trailer braking will cease Boost Setting The boost button was designed to allow a more aggressive setting for your trailer brakes and is available in three levels b 62 63 Each incremental boost setting increases the sensitivity of the Prodigy s inertial sensor enhancing the paticipation of the trailer brakes during a braking event The first press on
3. the boost button displays the current setting Boost is advanced to the next level by continuing to press the boost button Five seconds after setting the boost level the display will show Boost On Cc A indicating Boost On by the right most decimal For example With the boost off c during a braking event the power to the brakes starts out at zero and increases with deceleration With the boost on level 1 Z cmb be b3 Boost Setting continued b i during a braking event the power automati cally starts out at approximately 13 of the power setting and increases with deceleration With the boost on level 2 6 2 or with the boost on level 3 6 3 during a braking event the power automatically starts out at approximately 25 of the power setting and increases with deceleration Some cases where you might want to use the boost button e You like the trailer braking to LEAD the tow vehicle s braking e Towing a full vs empty trailer e Degraded brake performance most electric brakes require manual adjustment see Appendix A or a dealer for adjustment or repair NOTE Boost not intended to be used to take place of trailer brake adjustment or repair See the chart below for recommended Boost settings indicated with X for typical Trailer to Vehicle weight relationships Select your boost setting based on your towing situatio
4. the unit Do not lift or place supports on any part of the suspension system 3 With a screwdriver or standard adjusting tool Note Trailer Brake Adjustment procedures rotate the starwheel of the adjuster assembly to courtesy Dexter Axle expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn 2 Remove the adjusting hole cover from the adjust ing slot on the bottom of the brake backing plate Technical Assistance Call Toll Free 1 888 785 5832 or www tekonsha com P N 7689 REV H
5. 832 or www tekonsha com P N 7689 REV H basaa ELECTRONIC BRAKE CONTROL INSTRUCTIONS Instructions for Electronic Brake Control continued Reverse Reverse continued When backing a trailer you can cancel If boost was active the right hand decimal BOOST and HOLD for a period of three point will also be on After three minutes minutes This can be accomplished by pressing the BOOST and HOLD features will the boost button continuously for five seconds automatically return to your previous settings with the brake pedal depressed The display will indicate NOTE Returning to your previous settings prior to three minutes can be accomplished by e pressing the boost button Troubleshooting Chart Display Situation Probable Gause Flashes 2 times a second ora Trailer is connected and Prodigy loses steady display connection to battery ground Flashes 2 times per second Prodigy sees an overload condition during operation Flashes 2 times per second 1 Brake wire sees short during idle condition 2 Use of some test lights or non Tekonsha testers can cause this problem The lower two bars flash Prodigy is mounted at too low an angle EJ The upper two bars flash Prodigy is mounted at too high an angle Flashes for 15 seconds 1 Trailer not connected to tow vehicle 2 Trailer connected with open circuit on brake line 3 Trailer connector disconnected or corroded 4 Los
6. TION This control is not designed for use with electric hydraulic trailer brake systems Installation Guide A WARNING The Prodigy must be mounted from O degrees to 70 degrees nose up See Below In hilly terrain it is advisable to leave a margin at either extent to keep bars from coming on when going up and down hills When mounted near level the lower bars may come on during heavy acceleration see Trouble shooting Chart This will not affect the performance during braking Failure to install the Prodigy within these constraints may cause impaired performance Wiring Brake Control Your Prodigy brake control has a new and unique connector located at the back of the control This connector allows you two options to wire your brake control Option 1 Use Pigtail Wiring Harness included This harness can be installed by following the Generic Wiring Guide Option 2 Use a Ford Dodge or GM specific wiring harness If your vehicle came with a factory tow package that included a 7 way connector you can purchase a Tekonsha OEM wiring harness with the Prodigy connector on one end and your specific vehicle s connector on the other See Generic Wiring Guide for location of your vehicle s connector Display Readings after Wiring the Prodigy After successfully wiring your Prodigy you should see the following on the two digit display e Power to Prodigy without trailer connected Displays for 15 seconds then E changes
7. n driving preference and condition of your trailer brakes Typical Boost Settings For Optimal Performance with properly adjusted trailer brakes TRAILER WEIGHT compared to VEHICLE WEIGHT BOOST OFF INCREASING BOOST LEVEL 3 0 e Trailer weighs APPROXIMATELY SAME as Vehicle AXWARNING Do not exceed NOTE 1 Always warm the trailer s brakes before setting the power Warm trailer brakes tend to be more responsive than cold brakes To warm trailer brakes drive a short distance 1 4 mile at 45 MPH with manual lever engaged enough to cause trailer braking at a low level 2 44 WARNING The power should never be set high enough to cause trailer brakes to lock up Skidding trailer wheels can cause loss of directional stability of trailer and tow vehicle Gross Combined Weight Rating GCWR The power may need to be adjusted for different load weights and road conditions Not all trailer brakes will lock up due to various conditions However inability to lock up the brakes generally indicates the need for an inspection to determine the cause When the power is set correctly you should feel unified braking between the trailer and tow vehicle 6 44 WARNING Boost setting will be cleared under abnormally low battery conditions Check boost setting after starting vehicle Technical Assistance Call Toll Free 1 888 785 5
8. s of trailer brake magnet ground No display with manual or 1 Loss of power to Prodigy Blank pedal activation 2 Loss of ground to Prodigy Display No display until activation Prodigy is in power saving mode due to no motion for fifteen minutes No braking Power control set to 0 Power interruption while brake pedal is depressed Appendix A Trailer Brake Adjustment Note With drop spindle axles a modified adjusting Brakes should be adjusted after the first 200 miles OPN GUE OUT ESTEE AE SECA DOUG of operation when the brake shoes and drums have 4 Then rotate the starwheel in the opposite seated and at 3000 mile intervals or as use and direction until the wheel turns freely with performance requires The brakes should be adjusted a slight lining drag in the following manner 5 Replace the adjusting hole cover and lower 1 Jack up trailer and secure on adequate capacity the wheel to the ground jack stands Follow trailer manufacturers recom 6 Repeat the above procedure on all brakes mendations for lifting and supporting the unit Check that the wheel and drum rotate freely A WARNING Never crawl under your trailer unless it is resting on properly placed A WARNING Do not lift or support trailer on jack stands any part of the axle or the suspension system Follow the trailer manufacturers recommendations for lifting and supporting
9. to e Power to Prodigy with trailer connected and Boost Boost feature not engaged C engaged feature e Manual Knob Activated without trailer e Manual knob activated with trailer 5 4 denotes a hypothetical power output This value is set using the power knob Range is 0 0 to 13 volts This is an indication of voltage output to electric brakes 24 e Power to Prodigy but display is in power saving mode no motion or activity for at least fifteen minutes Blank Display Mounting the Prodigy 70 Traditional Bracket Mount A Mounting Bracket B 8 X 3 8 Machine Screw with Internal Tooth Washer 1 44 CAUTION Drilling or use of longer screws may damage unit 2 Securely mount bracket to a solid surface 3 Insert supplied 8 x 3 8 machine screws on each side into the mounting holes 4 Adjust control to desired position and tighten screws until snug Under Dash Pocket Mount A Pocket Mount B 6 X 1 2 Self Tapping Screws C Pocket Mount Template 1 Securely mount Pocket Mount to a solid surface using supplied 6 X 1 2 Self Tapping Screws 2 Insert Prodigy Brake control 3 Plug in connector Technical Assistance Call Toll Free 1 888 785 5832 or www tekonsha com P N 7689 REV H NOTE 1 Front of the Prodigy must be horizontal see below The Prodigy must be parallel to direction of travel see below Direction of Travel Direction of Travel Automatic
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