ELECTRONIC BRAKE CONTROLLER
HAYES BRAKE CONTROLLER P/N 81725
INSTALLATION MANUAL
For trailers with 2-4 electric brakes and
vehicles with 12 volt negative ground
systems only.
READ AND SAVE THESE INSTRUCTIONS
• Before beginning installation, read and become
familiar with these instructions.
• Leave these instructions in tow vehicle for future
reference.
• IMPROPER INSTALLATION AND OPERA-
TION COULD CAUSE PERSONAL INJURY
AND/OR EQUIPMENT AND PROPERTY
DAMAGES
• Questions on installation, adjustment, trouble
shooting or operation of brake controllers
• Call 800-892-2676 Monday through
Friday between 8:00 a.m. and 5 p.m.
Eastern Time.
SAFETY INFORMATION
WARNING: Indicates a potentially
hazardous situation that, if not avoided,
could result in death or serious personal
injury.
CAUTION: Indicates a potentially
hazardous situation that, if not avoided,
could result in damage to product or
property.
TIP: Contains helpful information to
facilitate installation.
The following chart describes the function of each of the controller’s wires:
Order Color Function Wire Size Connect To
(AWG)
1st White Ground 16 grounded metal part of the firewall or directly to the negative (-) terminal of the battery. Connect this wire first.
2nd Black + connection to the vehicle’s 12 positive (+) terminal of the battery. MUST have a self-resetting Circuit Breaker in-line between the controller and
power system the battery. See chart for proper size. Route the black wire through a grommet hole in the fire wall to prevent wire
grounding and away from the radio antenna to reduce any possible AM radio interference. Connect this wire second.
3rd Red Stoplight 14 non-powered stop lamp wire (of the stop lamp switch) or trailer tow wiring harness. It is recommended that a 20-amp
inline fuse be installed between the controller’s red wire and the stop lamp switch.
The fuse is required in 1999 & later Fords.
4th Blue Output to trailer brakes. 14 the trailer brake wire or tow vehicle / trailer connector.
IMPORTANT: Make all controller wiring connections to the wiring harness before connecting the harness to the vehicle.
WARNING:
1989 - 1991 Ford Bronco, Econoline, F-
Superduty, and F150-350 Series:
• The red stoplight wire must splice into the
turn signal connector harness and NOT in the
stoplight switch.
• Connecting to the stoplight switch will break the
switch and result in no stoplights and no trailer
braking.
WARNING:
All 1999 and later Ford vehicles
without the trailer wiring package:
• The red controller wire must be connected
to the light green wire of the brake stop light
through a 20-amp inline fuse.
• Failure to install a 20-amp fuse can destroy the
controller and void the manufacturing warranty.
4 Bulbs (minimum) 20 AMP 30 AMP
5 Bulbs 20 AMP 30 AMP
6 Bulbs 20 AMP 30 AMP
7 Bulbs 30 AMP 30 AMP
8 Bulbs 30 AMP 30 AMP
9 Bulbs 30 AMP 40 AMP
Note: Each trailer brake magnet is assumed to draw 3 amps of current and
each brake lamp bulb is assumed to draw 2 amps.
SELF-RESETTING CIRCUIT BREAKER SIZE CHART
Special Conditions
For tow vehicles equipped with factory trailer
towing package:
• Refer to your vehicle owner’s manual to deter-
mine the correct connection points for the
controller.
• See Appendix section for partial list of manufac-
turer wiring harness to controller conversions.
For vehicles
without a trailer-towing package:
refer to the wiring diagram in Figure 4.
APPENDIX
OEM TOW VEHICLE WIRING CONVERSIONS
CHRYSLER (THROUGH 2002) CONTROLLER FUNCTION CHRYSLER (NEW)
RED W/BLACK TRACE BLACK +12 VOLT SUPPLY WHITE W/ RED TRACE
WHITE W/TAN TRACE RED STOPLIGHT BLUE W/WHITE TRACE
BLUE BLUE TRAILER BRAKES BLUE
BLACK WHITE GROUND
GREEN W/BLACKTRACE
FORD (THROUGH 2002) CONTROLLER FUNCTION FORD (NEW)
RED BLACK +12 VOLT SUPPLY PINK
LIGHT GREEN RED STOPLIGHT RED
BLUE BLUE TRAILER BRAKES BLUE
WHITE WHITE GROUND WHITE
BROWN NOT USED ILLUMINATION BROWN
FORD EXPEDITION CONTROLLER FUNCTION
RED BLACK +12 VOLT SUPPLY
RED/GREEN TRACE RED STOPLIGHT
BLUE BLUE TRAILER BRAKES
BLACK WHITE GROUND
GENERAL MOTORS CONTROLLER FUNCTION
RED BLACK +12 VOLT SUPPLY
LIGHT BLUE RED STOPLIGHT
DARK BLUE BLUE TRAILER BRAKES
BLACK WHITE GROUND
BROWN NOT USED ILLUMINATION
2004 INFINITY CONTROLLER FUNCTION
RED BLACK +12 VOLT SUPPLY
RED/GREEN RED STOPLIGHT
BROWN/WHITE BLUE TRAILER BRAKES
BLACK WHITE GROUND
RED/BLUE NOT USED ILLUMINATION
RANGE ROVER CONTROLLER FUNCTION
REMOVE TAIL LIGHT AND BLACK +12 VOLT SUPPLY
CONNECT RED RED STOPLIGHT
CONTROLLER WIRE TO BLUE TRAILER BRAKES
BLACK/BLUE TRACE, NO WHITE GROUND
LIGHT WITH MANUAL NOT USED ILLUMINATION
2004 TITAN/ARMADA CONTROLLER FUNCTION
RED BLACK +12 VOLT SUPPLY
RED/GREEN RED STOPLIGHT
BROWN/WHITE BLUE TRAILER BRAKES
BLACK WHITE GROUND
RED/BLUE NOT USED ILLUMINATION
2004 TOYOTA TUNDRA CONTROLLER FUNCTON
BLACK-RED BLACK +12 VOLT SUPPLY
GREEN-WHITE RED STOPLIGHT
RED BLUE TRAILER BRAKES
BROWN WHITE GROUND
TIP:
• Special Dual - Mated “Quik-Connect” Wiring Harnesses are available for all Hayes Brake Controllers fitted with a connector on the
wire leads, making connection a snap. Harnesses are available through all dealer resources. Ask specifically for the Hayes Brake
Controller Company (HBC) brand harnesses to match your controller.
19003-3H
SYNCRONIZER
Number of Trailer Brakes
Number of Brake Light Bulbs
(tow vehicle Plus trailer)
2 Brakes 4 Brakes
Installation Steps
1. Install the mounting bracket to a solid surface
under the tow vehicle dash using the two
machine screws and fasteners provided.
Tighten until snug. See Figure 2- Acceptable
Mounting Angles and Figure 3 - Attachment of
Mounting Bracket.
2. Insert four of the self tapping screws provided
through the mounting bracket holes and into the
desired controller anchor holes. Tighten until snug.
3. Mount in a location, which allows the driver to
easily apply the manual override and see the
Red Indicator Light.
Read all wiring instructions prior to making
electrical connections to the tow vehicle.
WARNING
To reduce the risk of injury or damage
to property:
• Always connect the
white wire first and the
black wire second.
• All four controller wires must be connected
properly for the controller to operate correctly.
• Failure to connect the wires correctly can
cause loss of trailer braking.
WARNING:
• The white wire must be connected to a
known good ground (preferably the negative
battery post).
• Improper or no ground will result in poor
controller performance or lack of perfor-
mance altogether.
• Improper ground connection can destroy the
controller and void the manufacturer’s
warranty.
WARNING:
• Improper connections may result in no
trailer brakes or destroy the controller and void the
manufacturer’s warranty.
• Refer to the vehicle manufacturer or Hayes
Brake Controller at 1-800-892-2676 for the
latest controller red stoplight wire to stop lamp
switch connections.
CAUTION:
Follow wiring instructions.
• Improper wiring will destroy the controller
and void the manufacturer’s warranty.
CAUTION:
• DO NOT connect the black wire to any
vehicle power supply line or fuse panels that
could cause circuit overload or damage to
tow vehicle wiring and vehicle electronics.
• Route the black wire through a grommet
hole in the fire wall to prevent grounding
and away from the radio antenna to reduce
any possible AM radio interference.
Form # 7-2167
Mounting Angle & Direction
The Syncronizer can be mounted at any angle and in
any direction.
It must be mounted in a location
where the driver can see the Red Indicator Light.
The driver must be able to reach and operate the
manual slide.
Controller Mounting and Installation
Controller and Mounting Bracket
• The bracket provided is to be used for mounting
the controller to the tow vehicle.
• Use the reversible slotted bracket.
•
Use only the provided screws to attach the
bracket to the controller.
WARNING:
Use of longer screws than those
provided can damage the unit and
cause loss of braking.
WARNING:
• All four controller wires must be
connected properly for the controller to
operate correctly.
• Failure to properly connect all four wires can
cause loss of trailer braking.
• Improper wiring will destroy the controller and
void the manufacturer’s warranty.
CAUTION:
• Care must be taken to ensure that the
mounting surface is rigid enough to prevent
excessive vibration.
• Excessive vibration may result in poor perfor-
mance.
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