SERVICE MANUAL 440-1002
Contents
1. Installation Instructions Trailer Actuator Before Starting 1 Examine all trailer wiring to verify that it is in good condition and properly connected Be aware that the use of undersized wiring from the actuator to the brake magnets will result in reduced trailer braking 12 gauge wiring is recommended from the output of the CARLISLE actuator to the brakes on the trailer The ground side of the magnets also needs to be connected directly to the ground side of the trailer brake battery via the trailer wiring not by grounding the magnet to a ground connection to the trailer frame Inspect the trailer brakes to be sure they are in good condition and are properly adjusted Consult your trailer owners manual for instructions on how to adjust the trailer brakes The Electrastar unit contains sensitive electronics that must be protected Drilling additional holes in the housing or electrostatically painting the Electrastar unit or welding anywhere on the Electrastar unit will damage the unit making it inoperable and will void the manufacturer s warranty Always remove the Electrastar unit from the trailer before doing any welding repair or modifications to the trailer structure Mounting the Trailer Brake Actuator Trailer Brake Battery and Emergency Breakaway Switch 1 Position the trailer as if it were connected to the towing vehicle The actuator must be installed at a location on the trailer that is level to insure proper ope2. a valid claim exists contact the dealer distributor from which the Product was purchased 3 If it is deemed that the Product should be returned to Carlisle for inspection and warranty consideration the dealer distributor will make the claim through their Carlisle supplier 4 Carlisle can not be responsible for units returned directly by consumers TO MAKE A CLAIM 1 All claims must include proof of purchase information The required information is e Copy of receipt or itemized bill showing name and address of purchaser date of purchase e Product model number and serial number These are found on a label on the product e Bills or receipts from a legitimate dealer or repair center itemizing labor charges for replacement 2 All returns require a Return Merchandise Authorization number RMA Direct accounts can obtain an RMA by contacting Carlisle customer service at 812 336 3811 You will be asked to provide proof of purchase information per item 1 directly above 3 The direct account will return the Product prepaid and securely packed in proper packaging The Product must be free of mud dirt sand or other debris with the brake fluid completely drained The carton must be clearly marked with the RMA number when the Product is returned to the Company for inspection If the Company determines that the claim is valid the Product will be repaired or replaced or credit issued to Carlisle s direct account If a labor claim is made
3. e Push on the brake pedal One read light should come on Turn gain up to six green lights Push red button on controller Two or three red lights should come on If not contact your distributor Trailer lights flicker e Battery charger in the Electrastar is cycling on and off This may be eliminated by running a brown wire directly from the trailer plug to the brown wire on the Electrastar unit ECN 05103 Manual 440 1002 Rev C Page 8 of 10 K Carlisle Limited Warranty Industrial Brake and Friction LIMITED WARRANTY and LIMITATION OF LIABILITY Carlisle Industrial Brake amp Friction the Company warrants its trailer brake actuator products including but not limited to HydraStar HydraStar XL and ElectraStar Products under normal use and service to be free from defects in material and workmanship for a period not to exceed two years from the date of sale to the original consumer or to the first retail purchaser of a trailer or other towed device the Warranty Any receipts proof of purchase or other documents obtained at the time a Product manufactured by the Company is purchased from a dealer distributor should be retained This Warranty is not transferable The obligations of the Company under this Warranty shall be limited to crediting the account of Carlisle s direct buying Distributor or OEM trailer manufacturer replacing or repairing those Products which are determined to the satisfaction
4. of the Company to be defective in material and or workmanship within sixty 60 days from the date of receipt of such products by the Company Any replacements or repairs will be made at the Company s designated facility and at the Company s expense Returned product found not to be defective will be returned at the sender s expense This Warranty shall not extend to any Products or any parts thereof which have been improperly installed installed contrary to the provided instructions altered tampered with or the engineering and design of which have been changed in any way nor shall this Warranty extend to any defects arising from abuse misuse accident improper wiring or negligence of an installer or of the consumer Refer to the instruction manual packed with your unit Copies of the instruction manual are available on our website at www carlislebrake com A hard copy can be ordered from Carlisle for 15 00 by contacting customer service at 800 873 6361 EXCEPT AS EXPRESSLY SET FORTH ABOVE NO OTHER WARRANTY EXPRESS OR IMPLIED AT LAW OR IN EQUITY IS MADE BY THE COMPANY IN RESPECT OF THE PRODUCTS INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR OTHER WARRANTY AND ANY SUCH WARRANTIES ARE EXPRESSLY DISCLAIMED REGARDLESS OF WHETHER ANY REMEDY SET FORTH HEREIN FAILS OF ITS ESSENTIAL PURPOSE IN NO EVENT SHALL THE COMPANY BE LIABLE TO PURCHASE OR ANY THIRD PARTY FOR ANY LOST PROFI
5. output of the trailer brakes versus the towing vehicle i e gain and to manually apply the trailer brakes The in cab controller is easily installed by inserting its power plug into the cigarette lighter receptacle not an accessory power receptacle on the tow vehicle and turning the running lights on Note that the unit must be plugged in each time that the towing vehicle is started The unit will automatically check to make sure that the running lights are on and that the system is functioning as designed In the event that a problem is detected the unit will flash the yellow status light on the face of the unit and will make a series of audible beeps The number of beeps is an indication of the problem that the system has detected Count the number of beeps and check the chart on the back of the unit to obtain direction on possible causes of the problem see Section J Trouble Shooting Guide The unit must be unplugged each time the tow vehicle is taken out of the service and the running lights are shut off A series of rapid beeps from the unit is an indication that you either are driving without having your running lights on or that you forgot to unplug the unit when the vehicle was shut off ECN 05103 Manual 440 1002 Rev C Page 3 of 10 In Cab Controller operation is as follows GAIN SETTING Press either the UP arrow to increase the amount of trailer braking and the down arrow to decrease the amount of trailer braking The selected ga
6. Carlisle will issue credit to reimburse for up to one hour of labor not to exceed 70 00 to replace the defective unit If a claim is deemed invalid and the Product is found to work properly the account will be notified and no credit will be issued for the unit or labor Invalid Product will be returned to the submitter freight collect unless otherwise instructed ECN 05103 Manual 440 1002 Rev C Page 10 of 10
7. SERVICE MANUAL 440 1002 FOR ELECTRIC BRAKE ACTUATOR KIT This Document is Applicable to 381 7020 ACTUATOR KIT W IN CAB CONTROLLER 381 7021 ACTUATOR KIT W O IN CAB CONTROLLER 381 7022 IN CAB CONTROLLER KIT 496 166 BATTERY PACK IMPORTANT This actuator will not function correctly with any other brand or type of in cab controller Carlisle Industrial Brake and Friction 1031 East Hillside Drive Bloomington IN 47401 Phone 812 336 3811 Fax 812 334 8775 ECN 05103 Manual 440 1002 Rev C Page 1 of 10 Manual 440 1002 Table of Contents SECTION DESCRIPTION PAGE A Features 2 B Compatibility 2 C System Components Trailer Mounted Actuator 2 Trailer Mounted Brake Battery 3 Breakaway Switch 3 In Cab Controller 3 D Important Safety Messages 4 E Installation Instructions Trailer Actuator 5 F Actuator Wiring 5 G Installation Check Procedures 6 H DOT Inspection Note 7 l Replacement Parts List Mounting Dimensions 7 J Trouble Shooting Guide 8 K Carlisle Limited Warranty 9 A Features The Carlisle trailer brake actuator is a microprocessor based 12 Volt DC system for use on single two and three axle trailers equipped with electric brakes The CARLISLE actuator kit consists of a trailer mounted actuator a deep cycle 17 amp hour trailer brake battery an emergency breakaway switch and an in cab controller The CARLISLE actuator is unique in that it is totally trailer mounted The actuator
8. TS CONSEQUENTIAL EXEMPLARY INDIRECT PUNITIVE INCIDENTAL OR SPECIAL DAMAGES OR COSTS INCLUDING ATTORNEYS FEES OR LOSS OF GOODWILL RESULTING FROM ANY CLAIM INCLUDING BUT NOT LIMITED TO ANY CAUSE OF ACTION SOUNDING IN CONTRACT TORT NEGLIGENCE STRICT LIABILITY OR PRODUCTS LIABILITY REGARDING THIS AGREEMENT EVEN IF THE COMPANY HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES Certain jurisdictions do not permit limitations on the duration of a Warranty accordingly the limitations included herein may not apply This Warranty is expressly in lieu of all other express or implied Warranties and any and all other obligations or liabilities on the part of the Company There are no Warranties which extend beyond the description on the face hereof No dealer distributor employee or representative of the Company is authorized to modify this Warranty in any way or to grant any other Warranty If you have a problem with your Product see the next page ECN 05103 Manual 440 1002 Rev C Page 9 of 10 IF YOU EXPERIENCE A PROBLEM WITH YOUR CARLISLE TRAILER BRAKE ACTUATOR 1 Trouble shoot the unit as described in the owners manual If a copy of the manual is unavailable contact your dealer distributor or you can download the manual off our website at www carlislebrake com Additional hard copies of the manual can be ordered from Carlisle customer service for 15 00 each call 812 336 3811 2 If after trouble shooting it is believed that
9. Y PACK COMPLETE 12 VDC 17 A H DEEP CYCLE BATTERY ENCLOSURE HARDWARE BREAKAWAY SWITCH INSTRUCTION SHEET AND STRAPS NOT SHOWN 496 166 1 J Trouble Shooting Guide Controller beeps one time repeatedly e Low Battery Check for low battery by pulling breakaway pin Voltage should drop from 12 volts DC to 10 11 volts DC If drop is larger charge or replace battery Controller beeps two times repeatedly e Open Circuit Pull breakaway pin Make sure brakes are working If not check for loose or broken connections to brake magnets Controller beeps three times repeatedly e Short Circuit Check for bare wire or loose connections in ground Also check for power wires making contact with each other or grounded surface Controller beeps four times repeatedly e Overload Check for too many running lights or too many axles more than three heavy duty Controller beeps five times repeatedly Turn Lights On e Make sure that the trailer running lights are on e Make sure the in cab controller is plugged into the cigarette lighter receptacle not an accessory power receptacle e Check for bad connections in plugs on the trailer and towing vehicle e Make sure plug pins are tight and not worn from use or dragging on the ground e Make sure there is no corrosion Check ground connections Make sure trailer is grounded to towing vehicle and trailer battery Brakes do not work There are no beeps
10. connects to the wiring on the trailer and does not require any modifications or additions to the wiring on the tow vehicle Any vehicle that can connect to the trailer and power the trailer s lights can make use of the CARLISLE trailer brake actuator The in cab controller is provided by a pendant that plugs into the cigarette lighter not an accessory power receptacle on the tow vehicle No modifications to tow vehicle or to the tow vehicle wiring are required to make the in cab controller operate correctly Multiple vehicles can share a single in cab controller by simply moving the in cab controller from one vehicle to another Additional in cab control units are available and are compatible with all CARLISLE trailer brake actuators B Compatibility The CARLISLE trailer brake actuator should function properly so long as the towing vehicle can power the running lights and stop lights on the towed trailer Note that vehicles and trailers that have amber turn signals typically require the use of a tail light converter to insure proper operation The CARLISLE actuator draws approximately 1 3 amps of power from the tail light circuit to power the on board battery charger On trailers with multiple running lights it may be necessary to install a powered tail light converter to insure that adequate power is available to operate the trailer brake actuator C System Components Trailer Mounted Actuator The heart of the CARLISLE system is an elect
11. ery It is critical that the trailer brake battery is a deep cycle battery and has a minimum capacity of 17 amp hours Operation with a weak or discharged battery can cause the actuator to malfunction resulting in possibly serious or fatal injuries and or property damage Do not attempt to operate the unit if a low voltage condition is signaled WARNING The Carlisle electric brake actuator is not intended to function as a park brake When stopped for extended periods of time apply the towing vehicle park brake and release the brake pedal WARNING Failure to properly install protect operate and maintain the actuator system can cause a malfunction resulting in possibly serious or fatal injuries and or property damage WARNING The tow vehicle trailer tail amp running lights MUST BE TURNED ON BEFORE PERFORMING ANY TOWING for the actuator to operate correctly and for the breakaway battery to be recharged Failure to turn the lights ON can cause the actuator to malfunction or the breakaway battery to become discharged resulting in possibly serious or fatal injuries and or property damage WARNING Should any SYSTEM PROBLEM STATUS CODE signals occur immediately stop the tow vehicle trailer and make all necessary repairs see Section J Trouble Shooting Guide Failure to properly maintain the actuator system can result in possibly serious or fatal injuries and or property damage ECN 05103 Manual 440 1002 Rev C Page 4 of 10 E
12. es power to the trailer brakes in the event of an emergency breakaway Breakaway Switch The system also includes an emergency breakaway switch The breakaway switch is mounted on the trailer and is connected electrically to the trailer brake battery and to the CARLISLE actuator The switch is also connected mechanically to the tow vehicle When a breakaway condition occurs the plunger on the breakaway switch is pulled out by the tow vehicle thereby completing an electrical circuit between the trailer brake battery and the breakaway circuit on the CARLISLE actuator When a breakaway condition is sensed by the CARLISLE actuator the trailer brakes are automatically applied at full power In Cab Controller STATUS CODES STOP FLASH RATE CHECK FOR BRAKE GAIN STATUS 1 LOW BATTERY 2 OPEN CIRCUIT o 3 SHORT CIRCUIT 4 OVERLOAD RAPID TURN LIGHTS ON SEE SERVICE MANUAL O O O G G O O 0 0O O U UST OPERATE WITH RUNNING LIGHTS ON The in cab controller gives the vehicle operator a means to increase or decrease the amount of trailer braking It also provides both audible and visible indications of any problem detected by the internal monitoring system The in cab controller is equipped with colored LEDs to indicate gain setting green brake output red and system problem status codes yellow It also has pushbutton switches to adjust the
13. ette lighter receptacle not an accessory power receptacle A beeping sound should be heard and the in cab controller should display a rapidly flashing yellow light Turn on the light switch the sound and flashing light should stop If it continues to sound and flash recheck for 12 volts to the BROWN wire and or for correct GROUND circuit wiring ECN 05103 Manual 440 1002 Rev C Page 6 of 10 Repeatedly press the UP or DOWN arrow switches on the in cab controller From 1 to 6 Green LED indicators should glow to indicate that various gain settings are being selected Select maximum gain setting 6 Green LED press and hold the square red STOP switch From 4 to 6 red LED indicators on the controller should glow and the trailer brake lights should be illuminated Apply and release the tow vehicle brake pedal several times Each time the pedal is pressed from 1 to 3 red LED indicators should glow and the trailer brake lights should illuminate Checks with Tow Vehicle Engine Running USE EXTREME CAUTION 5 Select the maximum Gain Setting 6 green LED using the in cab controller Apply and HOLD the tow vehicle brake pedal release the park brake start the engine and place the transmission shift lever in Forward With the engine at low idle speed release the brake pedal enough to allow the tow vehicle to move slowly forward Apply a small force to the brake pedal The trailer brakes should be felt to apply noticeably s
14. in level will be shown by the number of green illuminated LED s on the face of the unit One light corresponds to the lowest setting six lights corresponds to the highest gain setting STOP BUTTON Press the red square STOP button to manually apply the trailer brakes Depending on the gain setting selected 1 to 6 red LED s will illuminate to indicate the level of braking being generated The brake lights on the trailer also automatically turn on whenever the manual brake button is depressed SYSTEM STATUS CODES Yellow status LED flashes audible alarm beeps of Beeps or Flashes Error Indication 1 Low Battery Voltage trailer brake battery 2 Open Circuit trailer wiring problem or brake magnet failed to open 3 Short Circuit trailer wiring or brake magnet shorted to ground 4 Overload actuator unit overheated RAPID Loss of Power tail running lights not turned ON D IMPORTANT SAFETY MESSAGES WARNING Thoroughly read and understand this manual before installation Failure to properly follow this manual could cause a malfunction resulting in possibly serious or fatal injuries and or property damage WARNING The brake system on the towed vehicle is intended only to supplement the tow vehicle brake system At no time should the towed vehicle brake system be relied upon to stop the towing vehicle WARNING All of the electrical power required to operate the trailer brakes is drawn from the trailer mounted brake batt
15. lowing the tow vehicle Repeat this procedure 2 3 more times Lower the gain setting to number 5 and perform Check Procedure 7 several more times trying various levels of applied pedal force Continue checking at various gain setting steps until you are thoroughly experienced at operating the system and have established the appropriate gain setting for the particular trailer involved H DOT Inspection Note To demonstrate that the actuator and trailer brake system are functioning properly adjust the up arrow on the in cab controller until the system is set at its maximum gain setting i e 6 green LED s illuminated Press and hold the red STOP button on the in cab controller and attempt to drive through the trailer brakes This will apply the maximum power to the trailer brake magnets and will demonstrate to DOT personnel that the trailer brakes are functioning properly l _Replacement Parts List Mounting Dimensions 10 57 n 9 94 i 1 25 2 50 H i i il 1 25 2X 8 213 MOUNTING 1 HOLES 1 8 69 A j 4 35 ECN 05103 Manual 440 1002 Rev C Page 7 of 10 REPLACEMENT PARTS LIST ITEM PART QTY DESCRIPTION 1 68 8632 2 GASKET ENCLOSURE END PARTS KIT REPLACEMENT IN CAB NOT SHOWN 381 7022 1 CONTROLLER TRAILER BATTER
16. ration Failure to properly level the unit may result in sporadic operation Select a mounting area for the actuator on the trailer that will provide easy access to the trailer brake battery the emergency breakaway switch and the trailer tow vehicle electrical connector The mounting location should give consideration to protecting the unit from road debris and from unnecessary abuse i e The unit should not be used as a step The long side of the actuator must be mounted parallel to the trailer centerline so that the wiring is directed to the front of the trailer Failure to properly align the unit may result in sporadic operation The actuator must be mounted in a horizontal position with the angled mounting brackets down As shown in Section Replacement Parts List Mounting Dimensions bottom view MUST BE PARALLE TRAILER CENTERLINE A ACTUATOR e Attach the actuator to the trailer by installing two 2 10 screws through the mounting holes The trailer brake battery can be mounted at any convenient location on the trailer Mount the battery enclosure with 2 0 25 inch diameter screws to trailer giving consideration to the fact that the battery is heavy and requires adequate support Mount the emergency breakaway switch on the tongue of the trailer providing for a direct mechanical link between the switch plunger and the towing vehicle Mount
17. ric brake actuator which includes a microprocessor and accelerometer The accelerometer is used to sense the amount of braking being generated by the towing vehicle Based on that input the microprocessor then automatically adjusts the output of the unit to generate a comparable amount of trailer braking Unlike a traditional electronic brake control the electrical power required to actuate the trailer brakes is drawn entirely from the trailer mounted brake battery 17 amp hour minimum capacity To insure that the trailer brake battery remains fully charged at all times a 3 amp battery charger is included an integral part of the trailer mounted actuator Power for that battery charger is drawn from the running light circuit on the tow vehicle Thus it is critical that the tow vehicle running lights are on whenever the ECN 05103 Manual 440 1002 Rev C Page 2 of 10 trailer is being towed Note that it is also critical that the trailer brake battery is not connected to any other charging circuit on the tow vehicle Connecting the trailer brake battery to a second charging source will cause sporadic operation and communication errors between the actuator and in cab controller Trailer Mounted Brake Battery All of the power for the trailer brakes is drawn from the trailer mounted trailer brake battery For proper operation the system needs a deep cycle battery with a minimum capacity of 17 amp hours Note that the trailer brake battery also provid
18. tch terminal Electrical Wiring Diagram BRAKES ACTUATOR J LH TURN SIGNAL YELLOW TOW VEHICLE TRAILER BRAKES TAIL LIGHTS BROWN TAIL LIGHTS BROWN LH TURN SIGNAL YELLOW RH TURN SIGNAL GREEN BREAKAWAY SWITCH RH TURN SIGNAL GREEN NEGATIVE GROUND WHITE BRAKE Li Li l BATTERY NEGATIVE GROUND WHITE BRAKES G Installation Check Procedures Checks With Tow Vehicle Engine NOT RUNNING Park Brake SET In Cab Controller Unplugged 1 Turn on the tow vehicle running light switch Verify that the trailer running lights are ON and that power is being supplied to the BROWN wire on the CARLISLE actuator Make any necessary repairs 2 Apply and release the tow vehicle brake pedal several times Each time the pedal is pressed the brake lights on both the tow vehicle and trailer should be illuminated and power should be supplied to both the yellow and green wires on the actuator Make any necessary repairs 3 Turn OFF the tow vehicle tail running light switch Activate the breakaway system by pulling out the breakaway switch plunger Verify that power is being supplied to the blue wire on the actuator and that the trailer brakes are functioning correctly Replace the plunger on the emergency breakaway switch In Cab Controller Operation 1 With the tail running light switch OFF plug the in cab controller cord into the cigar
19. the switch with a 0 25 inch screw F Actuator Wiring Connect the six wires from the trailer mounted actuator to the trailer wiring system as follows See Diagram WARNING Failure to wire the unit properly can result in damage to the trailer brake actuator Trailer Actuator Wires BROWN WIRE Connect the brown wire from the actuator to the tail light running light circuit on the trailer YELLOW WIRE Connect the yellow wire from the actuator to the left turn signal brake light circuit on the trailer ECN 05103 Manual 440 1002 Rev C Page 5 of 10 GREEN WIRE Connect the green wire from the actuator to the right turn signal brake light circuit on the trailer WHITE WIRE Connect the white wire from the actuator to the negative terminal on the trailer battery and to both a ground connection on the trailer and to the ground wire in the wiring harness from the tow vehicle The unit will not operate properly without a direct connection to the ground circuit on the towing vehicle Grounding between the trailer ball and coupler without a direct connection to the towing vehicle ground circuit will result in system errors BLACK WIRE Connect the black wire from the actuator to the positive terminal on the trailer battery and to one side of the emergency breakaway switch BLUE WIRE Connect the blue wire from the actuator to the positive side of the trailer brakes and to the remaining unused emergency breakaway swi
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