I found this on the WEB in regard to the NZ Maxbrake unit. Snoking
COMPLIES WITH BRAKE RULE 32015 FOR NZ CLASS TC TRAILERS
April 2012
HYDRAULIC INSTALLATION
INSTRUCTIONS
Thank you for buying a MaxBrake3, once installed we are confident you
will be happy with the performance. All components used in this
controller are SAE rated. This controller was developed exclusively for
the NZ market and complies with the current NZTA Brake Rule 32015/2
that states the following are not permitted for Class TC trailers;
Variable Proportioning Devices
The rule requires that no device is fitted which enables the driver to adjust the
brake force distribution between axles or vehicles used in a combination
[2.3(1)(b)]. So, any of these devices, which may be used by the engineer
when setting up the brakes for the combination, must be permanently set or
removed on certification.
Inertia/Timer operated Brakes
The rule requires that the service brake of a heavy vehicle, whether in
combination or not, must be able to be applied from the driver's normal
driving position in a controlled and progressive manner using one control
only, [2.3(1)(a) and 2.3(2)]. This means that any Inertia or timer service
brake controls fitted to a TC trailer must be replaced by a progressive control
operated from the same control as the service brake of the towing vehicle.
HOW THE MAXBRAKE3 WORKS
1 CM TRAILER EQUIPMENT
1. HYDRAULIC DUAL PRESSURE SENSOR INSTALLATION
Note: Installation must only be carried out by a qualified brake technician
Do not contaminate the brake system by allowing moisture or debris to enter.
1. Park vehicle on level, flat ground. Turn engine off. Ensure that vehicle will not move.
2. Locate brake master cylinder. (See vehicle owner's manual) and always use proper tools.
3. Carefully disconnect brake lines from brake master cylinder (Front & back port)
4. Note: Different vehicles have different hydraulic fittings. Connect the hydraulic Tee
adaptors as shown on the appropriate figure for your vehicles. You may need to gently
bend the brake lines to better fit your application. Be careful to prevent damage to your
brake system. Due to room constraints on some vehicles it may be necessary to tee into the
brake lines further away from the master cylinder. CM Trailer Equipment have brass tees to
fit most sizes of brake line.
5. Reconnect the vehicle brake line to the Tee adapters.
6. Attach the supplied brake pipes and pressure sensors to the remaining port on the Tee
adapters.
7. Bleed air out at the pressure sensors. (see bleeding instructions note 2)
8. Connect sensor cable to both sensors and feed sensor cable through vehicle firewall.
Caution: Do not pinch, crush, or damage the sensor cable. (If sensor cable is not long
enough, we recommend that you make a longer brake pipe between the tee and the
sensors, DO NOT cut and lengthen the sensor cable)
9. Connect sensor cable to MaxBrake brake controller.
10 You will need to calibrate MaxBrake one time for your vehicle, unless you change the
pressure sensor. See calibration instruction 4.
11. Be sure to check the brake fluid level in the reservoir after bleeding the pressure sensors.
Add fluid as necessary.
If you have trouble please contact CM TRAILER EQUIPMENT LTD PH 03 308 9918
Pressure Sensor
Union
Brake Line
Inverted Flare Tee
Vehicle Brake Line
Brake master Cylinder
MAXBRAKE 3 HYDRAULIC INSTALLATION INSTRUCTIONS 2
2. BLEEDING THE SENSOR
Once MaxBrake sensors are installed
1. Turn off the engine and allow to cool. Ensure that vehicle will not roll or move.
2. Take foot completely off the brake pedal. Note: Do not twist cable at the back of the
pressure sensor, unplug the pressure sensor cable.
3. Loosen the pressure sensor with a slight 1/4" turn. Be ready to collect brake fluid.
4. Have assistant very slowly begin to press brake pedal. Instruct the assistant in advance not
to release the brakes until instructed to do so.
5. Look for brake fluid to begin escaping at the threads of the pressure sensor. As soon as
brake fluid is observed, have assistant hold brake pedal steady.
6. Close the pressure sensor by tightening it. Plug in the pressure sensor cable.
7. Instruct the assistant to release the brakes. Note: Do NOT release the brake pedal while the
pressure sensor is open (not tightened), as this will suck air back into the system.
8. Be sure to check the brake fluid level in the reservoir after bleeding the pressure sensor.
Add fluid as necessary to keep the level above the fill line. Do not contaminate system.
9. Be sure to inspect the pressure sensor and other fittings for signs of leakage. Do not
operate a leaking or malfunctioning brake system. Correct leaks as necessary.
NOTE: Air bubbles in the brake lines can sometimes cause strange results.
3. ELECTRICAL WIRING
The MaxBrake controller is only to be used with 12 volt, negative ground systems. Do not
reverse polarity. (Not all vehicles use the same wire colours)
15 Amps current limit
BLACK + 12v supply from tow vehicle battery, hot at all times, fuse or circuit breaker
protected, 30 amps maximum.
WHITE - Negative ground return.
BLUE Output to trailer brakes.
3 CM TRAILER EQUIPMENT CAUTION: When charging or removing and replacing batteries, it is a necessary requirement to
disconnect the power supply from your Maxbrake controller. This can be done simply by removing
the 4 pin power plug from the rear of the unit. Disconnecting the power won't affect any of your
settings as the Maxbrake retains this in the memory. Disconnecting your Maxbrake will limit the
possibility of any damage being done to the electronic circuitry by way of; accidental reverse
polarity, charging spikes or short circuit. Any damage caused by these scenarios is clearly visible on
the circuitry and is not covered by Maxbrake's extensive warranty.
MAXBRAKE3 FRONT & REAR VIEW
BLK + 12V
WHT - GROUND
BLU Trailer Brake Magnets
or Electric/Hydraulic Actuator
CAL
NOTE A Electric/hydraulic trailer brake systems use the MaxBrake output as a very low
amperage power control signal, (a separate high current auxiliary supply wire to
power the electric pump motor must be installed). Refer to brake actuator
installation manual.
NOTE B Be very cautious about electrical connections with different colour codes, as
wire colours may vary from vehicle to vehicle.
NOTE C Solder all joints.
MAXBRAKE 3 HYDRAULIC INSTALLATION INSTRUCTIONS 4
Dual Function Knob for Adjusting Gain Control
& Activating Temporary Park Brake
24 VOLT - 12 VOLT ELECTRIC BRAKES SCHEMATIC FOR MAXBRAKE 3
BATTERY 1 BATTERY 2
12volt
CHARGE
EQUALISER
CE20
+12 volt circuit from tow vehicle
6 amp for 2 wheel brakes
12amp for 4 wheel brakes
On Trailer
Breakaway Battery
charger Common Ground
Trailer & Tow Vehicle
Breakaway Switch
Black
Blue / Black Black
Blue
White MaxBrake 3
In Cab Controller
Black
Self resetting circuit breaker
20amp for 2 & 4 wheel brakes
+12 volt
T
drum brake
magnets
White o electric
NOTE: 24 VOLT VEHICLES
Vehicles operating on a 24 volt
system must utilize a 24v to 12v
charge equalizer with a minimum
continuous load rating of 20
amps for the power supply to the
Maxbrake unit. Failure to do so
will void any warranty claim. CM
recommend the Redarc CE20
Charge Equalizer.
4. CALIBRATION
1 Make sure vehicle is at a complete stop.
2 Vehicle engine must be running.
3 Take foot completely off brake pedal.
4 Push & hold CAL button, wait until after the 5 second countdown is finished before
releasing the CAL button. You will see a message “Cal Mode”.
5 Dial up Gain G to specified rate between G1 & G100. Lower settings are soft, higher settings
are hard brake response. For initial set up & controller testing set between G40 & G45 until
you can discuss calibration with your HVEK certifying engineer.
6 Slowly press brake pedal until A & B on left side of screen increases to a maximum reading
of between 30 & 35. A & B readings are the pressure sensors and this is the recommended
setting.
NOTE: There will often be a difference between A & B, this is normal as the vehicle brake
system has a bias with more pressure to the front brakes.
7 Take foot completely off brake pedal.
8 Push & hold CAL button until message says “release Cal button”. Release Cal button.
9 Rotate Gain knob counter clockwise, never leave Gain knob rotated fully clockwise.
10 MaxBrake is now trained. Test to ensure that MaxBrake tracks with the brake pedal.
NOTE 1: If the brake pedal is not pressed there should be no figure at the top left corner of the
screen. If there is a figure please recalibrate. Numbers of between 1 & 999 should only appear
if the brake pedal is pressed. Refer to section 5 for brake output and screen readings.
NOTE 2: RESIDUAL HYDRAULIC LINE PRESSURE
Please note that on some applications of the Maxbrake3 it is required to be fitted to vehicles
equipped with air operated hydraulic brakes. This type of braking system is usually found on
the heavier types of trucks.
The Maxbrake3 sensors are still fitted in the normal manner to the hydraulic master cylinder.
However these types of braking systems are known to have residual hydraulic line pressure.
This means that when the brakes are inactive they still contain a small amount of pressure in
the brake lines.
The most important procedure to follow here when calibrating the Maxbrake3 is to make sure
that the vehicles air system is up to full operating pressure. Next step is to depress the brake
pedal a couple of times before you start your calibration mode. This will help charge the brake
lines. Now when you start calibration, the Maxbrake3 will zero the sensors, thus eliminating
this residual pressure reading.
If you fail to do this, the Maxbrake3 may pickup this residual line pressure and keep the trailer
brakes partially on when not using the tow vehicle brakes.
5 CM TRAILER EQUIPMENT
5. TESTING THE CONTROLLER OUTPUT VOLTAGE
A. WITH NO TRAILER CONNECTED
MaxBrake controllers transmit a very weak “ghost” detection Voltage, this is to detect trailer
plugged/unplugged. With trailer disconnected and no brake pedal pressure a voltmeter will
read approximately 4.5 Volts. “Check Trailer Wiring” appears on the screen. With any amount of
brake pedal pressure the output will read full battery Voltage, remember this is a “false” value
because the trailer is disconnected, MaxBrake will display between 1 – 999 in the top left corner
to indicate how hard the brake pedal is pressed. To test the controller requires an electrical load
of either a trailer with electric magnetic brakes or electric/hydraulic actuated brakes otherwise a
car horn will suffice. Once the controller detects sufficient resistance the output Voltage is:
NO PEDAL PRESSURE = 0 Volts (zero)
FULL PEDAL PRESSURE = 12 Volts/full battery Voltage with “G” gain set @ G100 or part thereof
depending on “G” setting. The higher the “G” gain setting the easier to test to full Voltage.
B. WITH TRAILER CONNECTED
To test controller voltage output connect to a trailer with an electric or electric/hydraulic brake
system; the controller requires a resistance load (see 5A above). Output voltage is;
NO PEDAL PRESSURE = 0 volts (zero)
FULL PEDAL PRESSURE = 12 volts/full battery voltage with “G” gain set @ G100 or part
thereof depending on “G” setting. The higher the “G” gain setting the easier to test to full
Voltage.
6. HOW TO OPERATE YOUR MAXBRAKE3
Once installed there are no further adjustments required. MaxBrake3 is calibrated and operated
in a controlled and progressive manner from the service brake of the towing vehicle and
complies with Heavy Vehicle Brake Rule 32015/2.
After a few minutes of inactivity, the MaxBrake display will turn off to save power. MaxBrake is
always on and ready when you need maximum braking power. Even with the display lit up,
MaxBrake only uses a trickle of only 0.05 Amps with the brakes off/inactive. With the display off,
MaxBrake draws about 0.02 Amps, so there is very little chance of draining your battery flat.
For all on-screen reporting “What Information Does MaxBrake3 Show On Each Screen” please
refer to section 8 below.
The only manual function of MaxBrake3 is the Temporary Park Brake Mode, please read
operating instructions below.
.
.
MAXBRAKE 3 HYDRAULIC INSTALLATION INSTRUCTIONS 6
7. TEMPORARY PARK BRAKE MODE
Park Brake Mode lets the driver temporarily “lock” the trailer brakes from the driver seat
before getting out and applying the trailer's mechanical park brake. This is required to meet
the new Brake Rule amendment 32015/2 for Class TC trailers.
NOTE: Disconnecting the trailer electrical cable from the tow vehicle will release the trailer park
brake.
NOTE: Also, electric powered magnetic drum brakes will release if the vehicle battery runs down.
TO USE THE PARK BRAKE FEATURES, FOLLOW THESE STEPS
1. With the tow vehicle engine running, set/lock the tow vehicle parking brake.
2. Press the brake pedal all the way down until brake output reads 999 and hold.
3. Rotate the gain knob fully clockwise.
4. The 6 second countdown will begin. The on-screen message shows “Setting Park Brake
in 6...5...4...3...2...1...0".
5. After countdown reaches 0 (zero), rotate gain knob counter-clockwise and release brake
pedal. On-screen message shows “Park Brake is ON”. If you release the brake pedal or
rotate the gain knob counter-clockwise before the countdown reaches 0 (zero), the
temporary park brake will not engage.
MaxBrake will display the approximate battery Voltage and how many minutes and hours have
elapsed with the park brake on.
If the battery Voltage drops below 11.5 Volts, MaxBrake will show “Low Battery” message.
If the battery Voltage drops below 10.0 Volts, MaxBrake will release the park brake to prevent
excessive battery drain.
MaxBrake will also release the park brake in the event of sensor cable unplugged, check trailer
wiring, or self test fail.
If the park brake releases immediately when attempting to set the park brake, watch for any
error messages to determine the cause.
TO RELEASE PARK BRAKE
1. On-screen message shows “Park Brake is ON”.
2. Press the brake pedal all the way down and hold.
3. Rotate the gain knob fully clockwise.
4. On-screen message shows “Releasing Park Brake in 6...5...4...3...2...1...0".
5. Rotate the gain knob counter-clockwise and release the brake pedal.
6. When the countdown reaches 0 (zero), the park brake will release.
.
7 CM TRAILER EQUIPMENT
If the park brake doesn’t release the probable cause is insufficient brake pedal pressure. Try
the above step again but with more brake pedal pressure.
NOTE: When used with electric/hydraulic actuators this park brake mode should not be left
running for more than 10 minutes as it may damage the actuator.
8. WHAT INFORMATION SHOWS ON EACH SCREEN?
NORMAL OPERATION
1. Top Left Corner shows brake output level from 1 to 999 when the brake pedal is pressed.
When the brake pedal is not pressed, no number should be displayed in the top left
corner.
If the brake pedal is not pressed AND a number is displayed in the top left corner, please
recalibrate MaxBrake.
2. “P” appears if the brake pedal switch is pressed, if connected.
3. Top Center show “MaxBrake”.
4. Top Right show the Gain setting G 0 (minimum) to G100 (maximum).
5. After 5 minutes of inactivity, MaxBrake will automatically switch off the display screen
light to save energy. This is normal.
6. A built in electronic eye will dim the display screen light during low light or night
conditions.
7. Error Messages are shown on the second line during normal operation.
“CHECK SENSOR CABLE” indicates that the sensor cable is damaged or unplugged from the
MaxBrake box
*Max Brake will not apply the trailer brakes when “Check Sensor Cable” is shown
“CHECK TRAILER WIRING” indicates an open circuit in the wiring between the MaxBrake box
and the trailer brakes.
The cause could be … The trailer electrical cable is unplugged from the tow vehicle (no trailer
connected)…. Or a poor electrical connection between the MaxBrake box and the trailer
brakes, …. Or unexpected stray voltages (such as trailer lighting circuits) due to improper
wiring, …. Or a poor electrical return path (bad earth) between the truck and the trailer,
“TRAILER SHORT” indicates an electrical short circuit with unsafe current levels
(approximately 25 or more Amps) which can permanently damage smaller electrical wires and
potentially cause and electrical fire.
MaxBrake will not apply the trailer brakes when “Trailer Short” is shown, but will monitor to see
if this fault condition is corrected.
MAXBRAKE 3 HYDRAULIC INSTALLATION INSTRUCTIONS 8
9 CM TRAILER EQUIPMENT “HIGH CURRENT” indicates that the trailer brakes are drawing too much current. This
MaxBrake product will limit the output current to about 15 Amps maximum in compliance with
New Zealand regulations, more than adequate for most trailer applications.
“BAD CALIBRATION” indicates that calibration was not done properly. The A or B number is
greater than 500 “ticks”. This could result in very low or weak trailer brake response. Please
follow the calibration instructions in the owner's manual.
“LOW BATTERY” indicates that the vehicle supply battery to the brake controller is below
10.0 Volts.
“SELF TEST FAIL” indicates an internal circuit failure inside the MaxBrake box.
“DUAL SENSOR ERROR” indicates that the two pressure sensors are not tracking together.
See the troubleshooting steps in the text above titled “Dual Pressure Sensors”
Calibration “CAL” Mode
Cal mode is used to train the pressure sensors with the brake pedal, and to set the gain value.
Cal mode has nothing to do with trailer errors, trailer disconnected, trailer connected, or
“Check Trailer Wiring”
When properly set, MaxBrake will operate very smoothly over a wide range of trailer braking
scenarios.
9. GENERAL INFORMATION
The MaxBrake brake controller is able to sense when the electric current loop is completed
through the vehicle body wiring, the trailer connector plug, the trailer wiring, and the trailer
brakes. If any part of this loop is broken, weak, or intermittent then the error message will
alert the driver on the MaxBrake display screen. MaxBrake cannot tell you exactly where the
problem is, but can alert you to potential problems that may limit your trailer brakes. If you see
the Trailer Unplugged / Check Trailer Wiring error message, you may need a qualified
electrician or service technician to troubleshoot and find the actual wiring problem in your
vehicle or trailer. Even with this error message displayed, MaxBrake will still make every
attempt to operate the trailer brakes, but no brake controller can operate the trailer brake
system that is disconnected or inoperative. This means the current loop is complete, but it may
be weak. Sometimes, other wires may be connected to the trailer brake wires by mistake.
99.9% of the time, the problem is not the MaxBrake brake controller. Try a different “known
good” trailer if possible to determine if it's the truck or trailer at fault. Because there are
various parts to this system, it can be difficult to pinpoint the exact cause of a wiring problem,
but it can be fixed by eliminating the most common causes.
After spending your hard earned money, it is very frustrating to have problems, but we have
actually seen brand new trucks, brand new trailers, and brand new wiring adapters that plug in,
MAXBRAKE 3 HYDRAULIC INSTALLATION INSTRUCTIONS 10
but do not work correctly with any brake controller. Most quality trucks, trailers, and wiring
adapters work great without any problems. If you do the wiring yourself, be sure to take pride
and care in your work. Proper wiring connections make a big difference. Trailer manufacturers
may use different wiring methods and you cannot always rely on all color codes to use the
same colors between all different trailers. Electricity does not care what color the wires are,
just that a reliable electrical loop is completed to the right places. Remember that vehicle
batteries and wiring are “live” and can cause more damage if not handled carefully. Other
brake controllers may indicate that there is no problem, but they might miss wiring problems
that MaxBrake detects. Our goal is to provide you with a quality product that works well, gives
you a lifetime of service, and detects faults early for your safety.
NOTE: After a few minutes of inactivity, the MaxBrake display will turn off to save power.
MaxBrake is always on and ready when you need maximum braking power. Even with the
display lit up, MaxBrake only uses a trickle of only 0.05 Amps with the brakes off/inactive. With
the display off, MaxBrake draws about 0.02 Amps, so there is very little chance of draining
your battery flat
10. MAXBRAKE LEGAL INFORMATION
MAXBRAKE LIMITED 5 YEAR WARRANTY
Mac's Classic Muscle Cars, LLC (hereafter referred to as “Mac's) warrants the MaxBrake brake
controller to be free of defects in material and workmanship, under normal use for a period of
five (5) years from the original consumer purchase date. At Mac's sole option, Mac's will repair
or replace the defective product with a like product. Replacement product or parts may include
remanufactured or refurbished parts or components. This warranty applies only to the first
consumer purchase, is nontransferable and limited to components supplied with the MaxBrake
brake controller product. The purchase or use of the MaxBrake brake controller constitutes
acceptance of the conditions stated in this document. Mac's makes no guarantee, warranty, or
representation regarding the suitability or legality of this product. It is the consumer's
responsibility to ensure regulatory compliance before purchasing or using this product. The
consumer agrees to operate this product in keeping with all laws governing its use. Under no
conditions will Mac's Classic Muscle Cars, LLC be responsible for anything other than the repair
or replacement of the original product.
LIMITATION OF LIABILITY AND WARRANTY EXCLUSIONS
Mac's liability is limited to the cost of repair or replacement of the MaxBrake brake controller.
This limited warranty excludes, but is not limited to, damage, deterioration, or malfunction due
to negligence, abuse, accident, improper use, misuse, improper installation, failure to follow
supplied instructions, alteration, modification, unauthorized repair or attempted repair,
For assistance with your MaxBrake controller, please call:
03 308 9918
For more information about MaxBrake please visit our website at
www.cmtrailer.co.nz
Phone 03 308 9918 - Freefax 0800 933 393
e-mail: -- email address removed --
www.cmtrailer.co.nz
15 Range Street qAshburton
Contact CM for your nearest stockist
external causes, normal wear and tear, or any other cause which does not relate to a product
defect. This limited warranty also excludes any incidental, consequential, or other claims,
damages, or losses, even if advised of the possibility of such, including against the consumer
by any party. There are no other warranties, express or implied, including implied warranty of
merchantability and fitness for a particular purpose. All disputes will be handled through
neutral arbitration.
TE195MB3MANUAL
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