Tuson TSC-1000 User manual

Installation Instructions
Tuson Sway Control
TSC-1000
475 Bunker Court
Vernon Hills, IL 60061 USA
800-968-8766
www.tusonaustralia.com.au
November 2018
US PAT. NO. 9,026,311 / 9,415,753
www.tusonrvbrakes.com
AUS PAT. NO. 2014204434 / 2016204948
Tuson RV Brakes, LLC
TUSON
Tuson Australia PTY LTD
TUSON
150 Northbourne Road
Campbellfield, VIC 3061 Australia
[phone]
Module
wiring
connector
on this
side.
Module will not function if improperly
positioned and/or oriented.
When
mounting,
this point
must be on
the trailer
center line.
Wires Trailer Wire
Function
Purple Left (driver's) side
electric brakes output
Pink Right (curb) side
electric brakes output
White Trailer battery/frame
ground point
Blue
Electric brake
controller signal from
tow vehicle
Black
12VDC from tow
vehicle trailer
harness
Vernon Hills, IL 60061
800-968-8766
www.tusonrvbrakes.com
!
Warning!
Read and follow all
directions in the
Installation Instructions
to ensure the unit
operates properly.
Designed and Engineered in the USA by Tuson RV Brakes, LLC
Tuson RV Brakes, LLC
TUSON
Mount this edge parallel with the trailer axle beams
approx. 1 to 10 feet back from trailer bumper hitch ball
ON A VERTICAL FRAME SURFACE
US PAT. NO. 9,026,311 / 9,415,753
Tuson Sway Control
(P/N: TSC-1000)
Mount with this side UP
AUS PAT. NO. 2014204434 / 2016204948

Tuson Sway Control (TSC)
Installation Instructions
It is essential that the
TSC be oriented in the proper
direction when it is installed.
1.1 Mounting Hardware:
The TSC should be mounted using the mounting flanges which are located on the bottom of the
unit. The customer is responsible for supplying the mounting bolts. Use four #10 self tapping screws with
star lock washers to mount the TSC to the trailer. It is recommended that star lock washers be
used and you must securely tighten the mounting bolts to hold the TSC firmly in position and to avoid
becoming loose from vibration.
You can NOT drill holes in the TSC for any reason. Drilling holes or puncturing the unit VOIDS
YOUR WARRANTY.
1.0 TSC Mounting Location:
TSC Label
DO NOT SPRAY HIGH PRESSURE WATER ON THE TSC. The TSC is a weather sealed,
water resistant unit but it is not designed to withstand direct, high pressure spray
from a power washer.
!
Page 1
Section One: Trailer TSC Mounting
Ensure the electric brakes are
adjusted and maintained in
accordance with the manufacturer's
recommendations in your owner's
manual for proper operation of the
sway control module.
!
Warning!
Warning!
Select a location on the trailer to mount the SCM. The location must be 5 to 10 feet behind the trailer bumper hitch ball and shielded from road debris. The SCM must be securely fastened onto a vertical surface of a steel trailer frame member to operate correctly. It must not be fastened to any other trailer surface that flexes or moves from wind to operate correctly. such as plastic covers or plastic walls. The center of the SCM (marked by a red dot on the SCM label – SEE BELOW) must be positioned on the “center line” of the trailer and the SCM wire harness must be pointing towards the LEFT (driver’s) side of the trailer. The longest edge of the SCM (as indicated by a red line on the SCM label) must be mounted parallel to the trailer axle beam(s). The SCM can be mounted on a vertical or horizontal surface as long as the positioning requirements previously described are met – SEE Figure 1 on page 2.
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Select a location on the trailer to mount the TSC. The suggested location is on the first trailer frame
crossmember approx. 1 to 10 feet behind the trailer bumper hitch ball and shielded from road debris. The
TSC can be mounted on either the “leading” or “trailing” edge of the crossmember as long as the correct
side is in the UP direction (as indicated on the label). The “trailing” edge is preferred since it provides the
best protection from road debris. The TSC must be securely fastened onto a vertical surface of a steel trailer
frame member to operate correctly. It must not be fastened to any other trailer surface that flexes or moves
from wind such as plastic covers or plastic walls. The center of the TSC (marked by a red dot on the TSC
label – SEE BELOW) must be positioned on the “center line” of the trailer. The longest edge of the TSC (as
indicated by a red line on the label) must be mounted parallel to the trailer axle beam(s). SEE Figure 1 on
page 2.
Module
wiring
connector
on this
side.
Module will not function if improperly
positioned and/or oriented.
When
mounting,
this point
must be on
the trailer
center line.
Wires Trailer Wire
Function
Purple Left (driver's) side
electric brakes output
Pink Right (curb) side
electric brakes output
White Trailer battery/frame
ground point
Blue
Electric brake
controller signal from
tow vehicle
Black
12VDC from tow
vehicle trailer
harness
Vernon Hills, IL 60061
800-968-8766
www.tusonrvbrakes.com
!
Warning!
Read and follow all
directions in the
Installation Instructions
to ensure the unit
operates properly.
Designed and Engineered in the USA by Tuson RV Brakes, LLC
Tuson RV Brakes, LLC
TUSON
Mount this edge parallel with the trailer axle beams
approx, 1 to 10 feet back from trailer bumper hitch ball
ON A VERTICAL FRAME SURFACE
US PAT. NO. 9,026,311 / 9,415,753
Tuson Sway Control
(P/N: TSC-1000)
Mount with this side UP
AUS PAT. NO. 2014204434 / 2016204948

Page 2
Section One: TSC Mounting, continued
Full Size +12V
Trailer Battery
Break-Away
Switch
-+
Frame
Ground
Left Front
Driver’s Side
Electric Brake
Left Rear
Driver’s Side
Electric Brake
Right Rear
Curb Side
Electric Brake
Right Front
Curb Side
Electric Brake
Mount on
trailer frame
crossmember
approx.
1 to10 feet
behind hitch
ball
Trailer
Centerline
TSC mounted
with the correct
side in the
UP direction
TSC Center on
Vertical Frame
Surface on Trailer
Centerline
Edge Parallel
with Axle Beams
1
Tuson
Sway
Control

2.2 Trailer Battery:
The trailer must be equipped with a full size 12
volt battery. Small, gel-cell type batteries
must not be used with the TSC.
Page 3
2.3 Ground Connections:
The tow vehicle ground, trailer battery ground,
trailer frame ground, TSC ground (white) wire
and the electric brake ground wires (on both
sides of the trailer) must all be securely
connected together with 14 gauge wire (min.) in
order for the TSC to function properly.
Section Two: TSC Wiring
Full Size +12V
Trailer Battery
Break-Away
Switch
-+
Frame
Ground
Left Front
Driver’s Side
Electric Brake
Left Rear
Driver’s Side
Electric Brake
Right Rear
Curb Side
Electric Brake
Right Front
Curb Side
Electric Brake
Must Use
Full Size
Trailer Battery
2
Tuson
Sway Control
Full Size +12V
Trailer Battery
Break-Away
Switch
-+
Frame
Ground
Left Front
Driver’s Side
Electric Brake
Left Rear
Driver’s Side
Electric Brake
Right Rear
Curb Side
Electric Brake
Right Front
Curb Side
Electric Brake
All Grounds
Connected
Together
3
Tuson
Sway Control

2.4 12 Volt Connections:
The tow vehicle 12 volt charge line, the 12 volt trailer
battery terminal and the TSC 12 volt (black) wire must
be securely connected together with 14 gauge wire
(min.) in order for the TSC to function properly. The
“hot” wire from the breakaway switch must be
connected to the +12V terminal of the trailer battery.
2.5 Electric Brake (Blue Wire)
Connections:
The tow vehicle brake signal (blue) wire must be
securely connected to the TSC brake signal (blue)
wire as well as to the “cold” wire from the
breakaway switch as shown in the wiring diagram.
Page 4
Section Two: TSC Wiring, continued
Full Size +12V
Trailer Battery
Break-Away
Switch
-+
Frame
Ground
Left Front
Driver’s Side
Electric Brake
Left Rear
Driver’s Side
Electric Brake
Right Rear
Curb Side
Electric Brake
Right Front
Curb Side
Electric Brake
12 Volt
Connections
4
Tuson
Sway Control
Break-Away
Switch
“Hot” Wire
Full Size +12V
Trailer Battery
Break-Away
Switch
-+
Frame
Ground
Left Front
Driver’s Side
Electric Brake
Left Rear
Driver’s Side
Electric Brake
Right Rear
Curb Side
Electric Brake
Right Front
Curb Side
Electric Brake
Brake
Signal
Wire
5
Tuson
Sway Control
Break-Away
Switch
“Cold” Wire

2.6 Left (driver’s side) and Right (curb side) Brake Wires:
The TSC operates the left (driver’s side) and right (curb side) trailer brakes independently in order to control trailer sway
and therefore it is very important that the correct TSC wires are connected to the correct side brakes. The TSC purple
wire must be connected to the left (driver’s side) electric brakes with a 14 gauge (min.) wire. The TSC pink wire must
be connected to the right (curb side) electric brakes. Failure to properly connect these wires will prevent the TSC from
controlling trailer sway.
Page 5
Section Two: TSC Wiring, continued
Full Size +12V
Trailer Battery
Break-Away
Switch
-+
Frame
Ground
Left Front
Driver’s Side
Electric Brake
Left Rear
Driver’s Side
Electric Brake
Right Rear
Curb Side
Electric Brake
Right Front
Curb Side
Electric Brake
Purple Wire
Left (Driver’s)
Side Brakes
6
Tuson
Sway Control
Pink Wire
Right (Curb)
Side Brakes

Page 6
Section Two: TSC Wiring, continued
Wire Connections to Trailer Plug
and system overview
YELLOW
Back-up
12 gauge
BLUE
Trlr. Brake Sig.
12 gauge
BROWN
Right Turn - Stop
12 gauge
WHITE
Ground
10 gauge
RED
Left Turn - Stop
12 gauge
BLACK
+12 Volts
10 gauge
GREEN
Running Lights
12 gauge
BARGMAN
Trailer
Connector
Full Size +12V
Trailer Battery
Break-Away
Switch
-
+
Frame
Ground
Running
Lights
Running
Lights
Running
Lights Running
Lights
Running
Lights
Running
Lights
Running
Lights
Left Turn -
Stop Light
Right Turn -
Stop Light
Left Front
Driver’s Side
Electric Brake
Left Rear
Driver’s Side
Electric Brake
Right Rear
Curb Side
Electric Brake
Right Front
Curb Side
Electric Brake
Wiring Diagram
Bumper Pull Trailer
Electric Drum Brakes
with Tuson Sway Control
Full Size +12V
Trailer Battery
= FRAME GROUND
(wires not shown)
= BREAKAWAY SWITCH
= TRAILER LIGHTS
(wires not shown)
= BACK-UP LIGHTS
(not used)
Tuson
Sway Control
The TSC mounts on a frame crossmember,
on the center line of the trailer, approx. 1 to 10 feet
back from the trailer hitch ball on a
VERTICAL frame surface.

TSC Wiring Harness
The TSC wire harness has five wires requiring electrical connection and one wire for the status LED light.
The function of each of these wires is outlined in the table below:
The 14 ga. wires of the TSC wiring harness are approximately 12 inches long to allow for flexibility when
mounting the unit. Extensions will be required to connect the unit to the trailer's electrical wiring. When
making connections to the trailer's wiring harness, the desired termination is a solder joint. If the
connection is not soldered, use the appropriate size and type of "crimp-type" weather sealed heat-shrink
connectors, using the manufacturer’s recommended crimping tools in accordance with their crimping
instructions. Once the 14 ga. wires are connected, route the Status Light wire to a location on the front
of the trailer and mount the Status Light Module onto a flat surface using self-tapping screws. Select a
location that makes it easy to see the Status Light when looking at the front of the trailer.
Taking shortcuts when connecting any wires on your trailer only increases the likelihood that some part
of your electrical system will fail. Make sure your splice connections are durable and sealed against
exposure to water and corrosive elements. One loose wire connection can disable your entire trailer
brake system.
When adding extension wires to the TSC wiring harness, you must use the correct gauge wire.
These gauge sizes are outlined in the table above.
TSC
Wires Trailer Wire Function Wire Gauge Required
Purple Wire Left (driver's) side electric brake
output (all driver's side brakes) 14 Ga. Minimum
Pink Wire Right (curb) side electric brake
output (all curb side brakes) 14 Ga. Minimum
White Wire Trailer battery/frame ground point 14 Ga. Minimum
Blue Wire Electric brake controller signal from
tow vehicle 14 Ga. Minimum
Black Wire 12VDC from tow vehicle trailer
harness 14 Ga. Minimum
Failure to use the correct gauge wire may result in poor braking performance or
brake failure. Improper wire gauge may also result in significant damage to your
trailer or its components, cause a fire, which may result in serious or fatal injury
and/or property damage. Undersized wire will prevent electrical circuit protection
devices such as fuses or circuit breakers from functioning properly. Undersized
wire may melt or burn before these safety devices can be activated.
!
Page 7
Section Two: TSC Wiring, continued
Warning!
Black Wire
10 foot wire with a two pin connector
on the end that plugs into the LED
status light
included in kit

Testing the TSC for correct wiring:
Page 8
Section Three: Functional Test Procedure
In order to verify that the TSC is wired correctly, follow the test process listed below:
WARNING!! IT IS VERY IMPORTANT THAT YOU FOLLOW THESE INSTRUCTIONS IN EXACT ORDER
TO PREVENT DAMAGE TO THE TSC!
1) Ensure that the trailer battery is fully charged or that a charging device is connected to the trailer via
the charge line and ground wire on the 7-way trailer connector.
2) Connect +12V from the tow vehicle via the charge line from the 7-way trailer connector and +12 volts
from the (+) side of the trailer battery to the BLACK wire on the TSC. Then connect the tow vehicle
ground from the 7-way trailer connector, the ground from the (-) side of the trailer battery, trailer frame
ground and the trailer brake grounds to the WHITE wire on the TSC.
WARNING!! VERIFY THAT THE TSC BLACK POSITIVE (+) WIRE AND THE WHITE GROUND (-)
WIRES ARE CONNECTED PER SECTIONS 2.3 AND 2.4 BEFORE PROCEEDING TO STEP 3.
3) Connect a brake controller to the brake signal (blue) wire of the trailer harness.
WARNING!! DO NOT PROCEED TO STEP 4 UNTIL +12V IS APPLIED TO THE TSC (+) BLACK WIRE.
4) Turn on the brake controller and apply the manual override until the TSC Status Light comes on.
If the Status Light does not light up, verify +12 volts is present on the black wire and that ground is
connected to the white wire. Also verify that the brake controller output is functioning properly and
that it is connected to the BLUE wire on the TSC.
5) Verify that the LED is GREEN and that it is “flickering”. This indicates no faults with the TSC. If the
LED is not GREEN, refer to the troubleshooting section on page 10 to correct the detected fault(s).
WARNING!! DO NOT PROCEED TO STEP 6 UNLESS THE GREEN LED IS ON AND FLICKERING!
6) Refer to Figure 1 on page 9 to verify correct wiring on the left side of the trailer. After the trailer passes
the left side test, reconnect the left side brake as normal before conducting the right side test.
NOTE: It is very important that the wire test connection is made back near the left side trailer
brake. Do not perform this test up front near the TSC since that will not verify correct
wiring back at the brakes.
7) Refer to Figure 2 on page 9 to verify correct wiring on the right side of the trailer. After the trailer passes
the right side test, reconnect the right side brake as normal.
NOTE: It is very important that the wire test connection is made back near the right side trailer
brake. Do not perform this test up front near the TSC since that will not verify correct
wiring back at the brakes.
8) If the TSC Status Light does not flash the correct number of times as indicated in Figures 1 and 2,
make the necessary wiring changes so that the flashes match the correct side.
WARNING!! ONCE BRAKE WIRING CONNECTIONS ARE CORRECTED, MAKE SURE TO REPEAT
STEPS 3,4,AND 5 BEFORE REPEATING STEPS 6 AND 7 TO VERIFY CORRECTED BRAKE WIRING.
9) After the trailer passes the tests as shown in Figures 1 and 2 and the brakes are reconnected as normal,
verify that the GREEN flickering light is displayed. If it is not, refer to the troubleshooting section on
page 10 to correct the detected fault(s).
The TSC performs a self-diagnostic test every time it “wakes-up” by receiving a signal from a brake controller
in the truck. The light may flash RED and GREEN approximately 6 times on startup and then go to GREEN.
The TSC also continually monitors system parameters during operation. If the system is operating
properly and no faults are detected, the GREEN light will remain ON and flicker or pulse. If a
problem is detected, a RED light will flash a specific number of times to indicate the specific problem.
The table on page 10 contains the meaning of the different RED and GREEN light flashes along with
troubleshooting suggestions to correct the problem(s). The TSC continues checking the fault status
and keeps the RED light flashing until the fault is corrected. Once corrected, the GREEN light
returns. NOTE: When the trailer is not moving, every 60 seconds the GREEN light will turn off
for 3 seconds and back on. This is normal and indicates proper operation of the TSC. If you
do not notice the GREEN light turning off and on every 60 seconds while the trailer is not moving,
have the TSC checked by your local service center.
The TSC Status Light Module:

Page 9
Section Three: Functional Test Procedure (cont.)
FIGURE 1
3 RED
Flashes
TSC
Status
Light
Module
Status
Light
Cable
Temp ora ri ly
connect the
Purple and
White wire
at ONE brake
location and
ver if y th e
status LED
flashes RED
3 times
LEFT Side
Bra ke Wi re s
PURP LE - B rake
Control
WHIT E - Grou nd
4 RED
Flashes
TSC
Status
Light
Module
Status
Light
Cable
Temp ora ri ly
connect the
Pink and
White wire
at ONE brake
location and
ver if y th e
status LED
flashes RED
4 times
RIGHT Side
Bra ke Wi re s
PI NK - B rake
Control
WHIT E - Grou nd
FIGURE 2

Page 10
Section Three: Status Light and Troubleshooting
GREEN
GREEN,
RED
Flashing
RED
TSC
Status
Light
Module
Status
Light
Cable
Mount the Status Light Module in a location on
the front of the trailer where the light is easily seen.
LEFT
SIDE
RIGHT
SIDE
LIGHT ACTION CONDITION CORRECTIVE ACTION
Solid GREEN
pulsing
Normal operation - no system
faults No action - system OK
1 GREEN flash
Module reset to mfg. default values.
Keep trailer sitting still for
minimum 30 seconds, then drive
normally.
If module does not return to
normal solid GREEN pulsing light
after 3 system restarts, have the
unit checked at a service center.
RED, GREEN,
RED, GREEN,
continuing…
Sway control automatically
disabled due to rough terrain
Unit will return to normal green
light when not on rough terrain
No light Unit in "sleep" mode Activate manual override on the
brake controller to "wake up" unit
No light No power after "wake up" from
brake controller
Verify the unit has good quality
power, ground and brake
controller wire connections. Check
for any blown fuses on the truck
and trailer.
No light Over voltage - over +20 volts
Check that power source is not
exceeding 20 volts - correct
voltage to 12-15 volts
No light Low voltage - under 3 volts
Check that power source is
12-15 volts. Verify good power
and ground connections
4 RED flashes Brake short (right side) Correct the short in right side
brake wiring
3 RED flashes Brake short (left side) Correct the short in left side
brake wiring
2 RED flashes Sensor malfunction - no sway
control Service center repair required
1 RED flash System malfunction Service center repair required
Fast RED flashing Low voltage - between 3 to 6 volts Check the power and ground
connections

Page 11
Section Four: How The TSC Works
How it Works
 The Tuson Sway Control (TSC)
continuously monitors trailer yaw.
 It has a proprietary algorithm
which is used to determine the
difference between quick steering
to avoid a road obstacle (or other
such circumstances) and the rapid
onset of a trailer swaying event.
 It measures the angle, travel
distance and speed of the lateral
motion of the trailer (and other
parameters) and uses this
information to quickly intervene
with the application of trailer
brakes.
 The processing capability of the
TSC is powerful and rapid.
It captures all the critical elements
of the swaying condition and uses
this information to predict how the
event will proceed without any
driver intervention.
 It uses this data to get ahead of
the event by applying the brakes
on the correct side of the trailer, in
a timely manner, with the proper
braking level for the required
duration.
 This quickly dampens and brings
the trailer sway under control.
Tuson Sway Control is based on the
same technology used in automotive
vehicle stability systems.
The Tuson Sway Control
applies the trailer
brakes in a manner to
dampen and control a
trailer swaying event.
Ensure the electric brakes are adjusted
and maintained in accordance with the
manufacturer's recommendations in
your owner's manual for proper
operation of the sway control module.
Important
Brake controller
blue wire.

Limited Warranty
Tuson RV Brakes, LLC (Tuson) warrants the Tuson Sway Control (TSC) to be free of 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 on which the TSC is installed. Original receipt(s) or other
acceptable proof of purchase should be retained by the customer for verification of warranty date. THIS
WARRANTY IS NOT TRANSFERABLE.
Tuson’s obligations under this warranty shall be limited to crediting the account of a direct buying distributor or
OEM trailer manufacturer, replacing or repairing the TSC products which are determined by Tuson to be
defective in material or workmanship, within 60 days of receipt of such product by Tuson. Tuson reserves the
right to request the product be returned intact, freight prepaid, PRIOR to processing any claim for warranty.
Warranty claim must be received by Tuson within 30 days of the discovery of the alleged defect, or within 30
days of the expiration of the warranty, whichever is earlier. Covered repairs or replacements will be made at
Tuson’s expense. Shipment of replacement product or repaired product by Tuson will be via best available
ground shipment carrier. Shipments other than by best available ground shipment carrier, must be requested in
writing and must be paid for in advance by the customer. Returned product that is found not to be defective,
will be returned at senders expense.
This Warranty shall not include any products which have been improperly installed, installed contrary to
installation instructions provided with the product, altered, tampered with or changed in any way, or utilized in
a manner not approved by Tuson. This Warranty shall not extend to any defects arising from abuse, misuse,
accident, improper wiring, or negligence of the installer or the consumer. Refer to the Tuson Sway Control
“Installation Instructions” that was shipped with the Tuson Sway Control.
EXCEPT AS EXPRESSLY SET FORTH ABOVE, NO OTHER WARRANTY, EXPRESS OR IMPLIED, AT LAW OR IN
EQUITY, IS MADE BY TUSON CORPORATION IN RESPECT OF THE PRODUCT, INCLUDING WITHOUT LIMITATION
ANY IMPLIED WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER
WARRANTY, AND ANY SUCH WARRANTIES ARE EXPRESSLY DISCLAIMED.
IN NO EVENT SHALL TUSON BE LIABLE TO PURCHASER OR ANY THIRD PARTY FOR ANY LOST PROFITS,
CONSEQUENTIAL, EXEMPLARY, INDIRECT, PUNITIVE, INCIDENTAL, OR SPECIAL DAMAGES OR COSTS
(INCLUDING ATTORNEY FEES), OR LOSS OF GOOD WILL RESULTING FROM ANY CLAIM (INCLUDING BUT NOT
LIMITED TO ANY CAUSE OF ACTION SOUNDING IN CONTRACT, TORT, NEGLIGENCE, STRICT LIABILITY OR
PRODUCT LIABILITY) REGARDING THIS AGREEMENT, EVEN IF THE COMPANY HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH DAMAGES.
Some states do not allow the exclusion or limitation of implied warranties, incidental or consequential damages,
so the above limitations or exclusions may not apply to you. This Warranty gives you specific rights. You may
have other rights, which vary from state to state.
Page 12