Instruction Booklet STALLER: GIVE THESE STRUCTIONS TO THE OWNER AFTER STALLATION FOR THEIR FURURE REFERENCE TAIL LIGHT WIRG KIT -- BASIC -- 1
LIMITED WARRANTY June 01, 2002 REMCO RECREATIONAL EQUIPMENT MANUFACTURG CORPORATION warrants their products to the original purchaser for a period of one (1) year from the original date of purchase. REMCO WARRANTS THEIR PRODUCTS AGAST DEFECTIVE MATERIALS AND WORKMANSHIP. THIS WARRANTY IS VOID IF THE PRODUCT IS DAMAGED BY ACCIDENT OR UNREASONABLE USE, NEGLECT, IMPROPER SERVICE OR OTHER CAUSES NOT ARISG OF DEFECTS MATERIAL OR WORKMANSHIP. THIS WARRANTY IS NOT SUBJECT TO MISUSE, ABUSE, ASSIGN OR TRANSFER. REMCO will either repair or replace during the above one (1) year all defective parts. Defective parts must be delivered or shipped prepaid and insured to REMCO. Parts must be accompanied with proof of date and place of purchase. The exclusive remedy under any and all warranties and guarantees expressed or implied is limited to the repair and/or replacement as provided herein. In no event shall REMCO be liable for any indirect, incidental, special, exemplary, punitive or consequential damages of any nature whatsoever, including, without limitation, any such damages for loss of profits, loss or delay of equipment use or other intangible damages. REMCO reserves the right to make changes and/or improvements in the product at any time without notice. REMCO shall not be obligated to incorporate such changes and/or improvements in products previously sold, nor be obligated to replace previously sold products with products incorporating such changes and improvements. No person, agent, distributor, dealer or company is authorized to change, modify or extend the terms of these warranties in any manner whatsoever. Notwithstanding any maximum limitation periods set forth under any applicable law or statute, the time within which an action must be commenced to enforce any obligation of REMCO arising under this warranty or under any applicable statute or law is hereby limited to the duration of the warranty set forth above, commencing from the date of purchase. ALL WARRANTIES IMPLIED BY STATE LAW, CLUDG THE IMPLIED WARRANTIES OF MECHANICABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THE LIMITED WARRANTIES SET FORTH ABOVE. WITH THE EXCEPTION OF ANY WARRANTIES IMPLIED BY STATE LAW AS HEREBY LIMITED, THE FOREGOG WARRANTY IS EXCLUSIVE AND LIEU OF ALL OTHER WARRANTIES, GUARANTEES, AGREEMENTS AND SIMILAR OBLIGATIONS OF MANUFACTURER OR SELLER WITH RESPECT TO THE REPAIR OR REPLACEMENT OF ANY PRODUCTS OR PARTS. This warranty gives you specific legal rights and you may also have other rights which may vary from state to state. Some states do not allow limitation on how long an implied warranty lasts, when an action may be brought, or the exclusion or limitation of implied warranties or incidental or consequential damages, so the above provisions may not apply to you. The foregoing warranty and the sale of the REMCO products to you shall be governed by and construed in accordance with the laws of the State of Nebraska (U.S.A.), without regard to principles of conflicts of laws, and you irrevocably consent to and submit to the exclusive jurisdiction and venue of the state and federal courts in Omaha, Nebraska, for the purpose of all legal proceedings arising out of or relating to the foregoing warranty and the sale of the REMCO products to you. 2
STALLATION STRUCTIONS REMCO TAIL LIGHT WIRG KIT WITH TAIL LIGHT DIVERTERS The REMCO Tail Wiring Kit connects the indicator lights from the motorhome to the indicator lights of the towed vehicle. The kit performs this function by the use of an external tow harness and solid state tail light diverters that will automatically switch from the towed vehicle s electrical system to the motorhome s system any time the towed vehicle is plugged into the motorhome. NOTE: Some motorhomes have separate turn signals and brake lights, which are identified by amber turn signals and red brake lights (4-wire tail light system). This type of system will require the use of an additional tail light converter that converts the 4-wire system to a 3-wire system (combined turn signals and brake lights). The converter is not supplied with this kit but is available through REMCO (MME PL-100, p/n 40010048) or your local supply center. Check the parts in the kit against the parts list to familiarize yourself with each item and to ensure all parts are included. TAIL LIGHT KIT BASIC The REMCO Tail Wiring Kit parts list: 1 26ft., 4-conductor cable with a molded flat plug on one end and a molded flat socket on the other. 4 Solid state tail light diverters 12 ¼ female terminals 2 Seamed spade terminals 6 Plastic wire ties 4 Self-stripping wire tap connectors 1 ¼ x ¾ self-tapping sheet metal screw (used for grounding) 3
GENERAL FORMATION NOTE: Prior to installation, determine which taillight wiring system you have on the towed vehicle: a 3- or 4-wire system. A 3-wire system has combined turn signals and brake lights (red turn signals). A 4-wire system has separate turn signals (usually amber) and brake lights. In this system you will use the brake light bulbs as your turn signals and brake lights for towing. STALLATION OF DIVERTERS FOR 3-WIRE SYSTEMS NOTE: Refer to Diagram 1, page 5 for the following steps. NOTE: This system will use 3 of the 4 diverters provided in the kit. The preferred location for the solid-state diverters is as close to the taillight assembly kit as possible. Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Access the wires for the taillight assembly (usually through the trunk in a sedan and wagon). It may be necessary to remove the lens assembly. Turn ON the taillights. Ground the continuity tester to a suitable ground. Probe each wire to locate a HOT wire. Turn OFF and ON the taillight switch to verify the correct wire on each side. Label the wires TAILLIGHTS. Turn OFF the taillights. Turn ON the left turn signal. Probe each wire for a HOT wire. Watch for the continuity tester to blink with the turn signal to verify the correct wire. Label the wire LEFT TURN. Follow the same procedure for the right turn signal, but label the wire RIGHT TURN. Turn ON the taillights. Locate the wires labeled TAILLIGHTS. Cut the wire and confirm that the taillights have gone. Turn OFF the taillights. Strip each wire ¼. Crimp a ¼ female terminal onto each wire. Connect the wire that goes to the taillight bulb to the of the diverter, connect the remaining wire to either terminal of the diverter. 4
Step 9. Turn ON the left turn signal. Locate the wire labeled LEFT TURN. Cut the wire and confirm that the turn signal light has gone. Step 10. Strip each wire ¼. Crimp a ¼ female terminal onto each wire. Step 11. Connect the wire that goes to the turn signal bulb to the terminal of the diverter, connect the remaining wire to either terminal of the diverter. Locate the wire labeled RIGHT TURN and follow the same procedure. Chassis Ground Ground White Rt Turn/Brk Green Right Turn/ Tail s Brown Brake Lt Turn/Brk Yellow Wiring from Motorhome Tail s Existing wiring on car Right Turn/Brk Tail s Left Turn/Brk Left Turn Brake DIAGRAM 1 3-WIRE TAILLIGHT SYSTEM STALLATION OF DIVERTERS FOR 4-WIRE SYSTEMS NOTE 1: This system uses all 4 diverters supplied in this kit. NOTE 2: With some vehicles, the taillight assembly must be removed to gain access to the taillight wires. NOTE 3: The amber turn signals are not used, instead, the brake lights become the turn signals and brake lights for towing only. NOTE 4: Refer to DIAGRAM 2, page 7, for steps listed below. 5
Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Start at the driver side taillight assembly. Access the wires for the taillight assembly. Turn ON the taillights. Ground the continuity tester to a suitable ground. Probe each wire to locate a HOT wire. Turn OFF and ON the taillight switch to verify the correct wire. Label the wire LEFT TAILLIGHT. Follow the same procedure for the passenger side taillight assembly, but label the wire RIGHT TAILLIGHT. Turn OFF the taillights. Have an assistant depress the brake pedal. Start at the driver side taillight assembly. Probe each wire for a HOT wire. Have the assistant depress the brake pedal ON and OFF to verify the correct wire. Label the wire LEFT TURN/BRAKE. For the passenger side taillight assembly, follow the same procedure, but label the wire RIGHT TURN/BRAKE. Refer to DIAGRAM 2, page 7; return to the driver side taillight assembly. Turn ON the taillights; locate the wire labeled LEFT TAILLIGHT. Cut the wire. Confirm that the taillight goes. Turn OFF taillights. Strip each wire ¼ crimp the ¼ female terminals onto each wire. Connect the wire that goes to the taillight bulb to the terminal of the diverter. Connect the remaining wire to either terminal of the diverter. For the passenger side taillight assembly, locate the wire labeled RIGHT TAILLIGHT and follow the same procedure as above. Return to the driver side taillight assembly. Have the assistant depress the brake pedal. Locate the wire labeled LEFT TURN/BRAKE. Cut the wire. Confirm that the brake light goes. Strip each wire ¼. Crimp the ¼ female terminals onto each wire. Connect the wire that goes to the brake light bulb to the terminal of the diverter. Connect the remaining wire to either terminal of the diverter. For the passenger side taillight assembly, locate the wire labeled RIGHT TURN/BRAKE and follow the same procedure as above. Install conductor cable. 6
Right Brake Right Tail Existing Wiring on car Left Tail Left Brake DIAGRAM 2 4-WIRE TAILLIGHT SYSTEM, EXISTG WIRG ON CAR AMBER TURN SIGNALS NOT SHOWN BECAUSE THEY ARE NOT USED STALLATION OF CONDUCTOR CABLE FOR 3- AND 4-WIRE SYSTEMS NOTE: The conductor cable is shipped in a continuous 26 ft. loop with a flat 4- conductor molded plug at one end and a flat 4-conductor molded socket at the other end. The 4-conductor cable is routed from the front of the towed vehicle back to the location of the diverters. To efficiently use the length of cable, either use the 4-conductor plug or socket at the front of the towed vehicle, either attached to the front of the towed vehicle or long enough to reach from the towed vehicle to the motorhome and stored coiled up in the engine compartment of the towed vehicle. If the 4-conductor plug or socket is attached to the towed vehicle, you can make a connector cable to connect the towed vehicle to the motorhome. MAKG A CONNECTOR CABLE Step 1 Step 2 Decide whether the molded plug or the molded socket of the conductor cable is to be used at the front of the towed vehicle. Cut the conductor cable about 6 7 ft from the plug or socket. 7
Step 3 The cut end of the connector cable will need to have a plug wire on to it to match the socket on the motorhome (this plug and socket are not included in this kit). Refer to the motorhome wiring to correctly attach the wires. NOTE: The connector cable will be used for testing the diverter and conductor cable installation of the towed vehicle. CONDUCTOR CABLE COILED UP TOWED VEHICLE S ENGE COMPARTMENT Step 1 Step 2 Step 3 Allow 7 9 ft of conductor cable between motorhome and towed vehicle to be sure you can couple the towed vehicle to the motorhome with the tow bar. Measure the conductor cable between the motorhome and towed vehicle to be sure. Cut 2 3 ft. from one end of the conductor cable. This length of conductor cable will be used to wire the motorhome (if necessary) and connect to the towed vehicle. After installation of conductor cable the excess with plug or socket will be coiled up in the towed vehicle s engine compartment. NOTE: The motorhome cable will be used for final testing of the diverter and conductor cable installation. STALLATION OF CONDUCTOR CABLE FOR 3-WIRE SYSTEMS NOTE: Refer to DIAGRAM 1, page 5 for the steps listed below. Step 1. Step 2. Step 3. Step 4. Route the conductor cable from the socket to the diverters. Separate the towed vehicle s conductor cable sufficiently to attach to the diverters. Strip each wire ¼. Crimp a ¼ female terminal onto the yellow, green, and brown conductor wire. Locate the TAILLIGHT diverter. Connect the brown conductor wire to the remaining terminal of the diverter. 8
Step 5. Step 6. Locate the LEFT TURN diverter. Connect the yellow conductor wire to the remaining terminal of the diverter. Locate the RIGHT TURN diverter. Connect the green conductor wire to the remaining terminal of the diverter. STALLATION OF CONDUCTOR CABLE FOR 4-WIRE SYSTEMS DRIVER SIDE RG OF CONDUCTOR CABLE NOTE 1: Refer to DIAGRAM 3, page 10 for the following steps. NOTE 2: For driver and passenger side conductor cable installation, two separate wires will be routed between the driver side taillight assembly, either inside the trunk area or underneath the vehicle. Step 1. Step 2. Step 3. Step 4. Route the conductor cable from the socket underneath the vehicle along the driver side to the driver side taillight assembly. Separate the conductor cable wires sufficiently to attach the diverters; strip each wire ¼. Crimp a ¼ female terminal onto the yellow conductor wire. Connect the yellow conductor wire to the remaining terminal of the LEFT TURN/BRAKE diverter. Crimp a yellow female terminal onto the red wire of the two-conductor wire and one to the brown wire of the three-conductor wire. Connect it to the remaining terminal of the LEFT TAILLIGHT diverter. Attach the green wire of the three-conductor wire to the black of the two-conductor wire with a butt connector provided. On the passenger side separate the two-conductor wire about 3-4, strip back about 3/8 and crimp ¼ female terminals on these ends. The red will go to the passenger side taillight diverter. The black will go to the passenger side turn signal/brake light diverter. Test the diverter and conductor cable installation. STALLATION OF CONDUCTOR CABLE FOR 4-WIRE SYSTEMS PASSENGER SIDE RG OF CONDUCTOR CABLE NOTE: Refer to DIAGRAM 4, page 11 for the following steps. 9
Step 1. Step 2. Step 3. Step 4. Route the conductor cable from the socket underneath the vehicle along the passenger side to the passenger side taillight assembly. Separate the conductor cable wires sufficiently to attach the diverters. Strip each wire ¼. Crimp a ¼ female terminal onto the green conductor wire. Connect the green conductor wire to the remaining terminal of the RIGHT TURN/BRAKE diverter. Crimp a yellow female terminal onto the red wire of the two-conductor wire and one to the brown wire of the three-conductor wire. Connect it to the remaining terminal of the LEFT TAILLIGHT diverter. Attach the green wire of the three-conductor wire to the black of the two-conductor wire with a butt connector provided. On the passenger side separate the two-conductor wire about 3-4, strip back about 3/8 and crimp ¼ female terminals on these ends. The red will go to the passenger side taillight diverter. The black will go to the passenger side turn signal/brake light diverter. Test the diverter and conductor cable installation. Right Tail White Brown Wiring from 6-Pole Socket To Chassis Ground Spliced Wire (by customer) Right Turn Left Turn Green Yellow Left Tail DIAGRAM 3 DRIVER SIDE RG (NOTE: AMBER TURN SIGNALS ARE NOT USED) 10
Green Right Tail Yellow Brown Right White Turn To Chassis Ground Spliced Wire Wiring from (by customer) 6-Pole Socket Left Turn Left Tail DIAGRAM 4 PASSENGER SIDE RG (NOTE: AMBER TURN SIGNALS ARE NOT USED) 11
REMCO HAS THESE PRODUCTS FOR YOUR TOWG CONVENIENCE REMCO S Drive Shaft Coupling is for automatic transmissions with rear wheel drive. REMCO S Lube-Pump lubricates and cools the automatic transmission of a front wheel drive vehicle while towing. REMCO S Axle Lock is for disconnecting the automatic transmission of a front wheel drive vehicle. REMCO S Tail Wiring Kit is for easy hook up of your tail lights and turn signals for towing. 4142 South 89 th Street PO Box 27998 Omaha, Nebraska 68127 1-800-228-2481 402-339-3398 12