Installation Instructions for Brake Control Plugin Wiring Harness (Part 20127/8506920)

Tools Required:

• Wire Stripper & Cutter
• Pliers

Overview:

This brake control plugin wiring harness is designed for quick and secure connections to your brake controller. It simplifies installation by matching functions and connecting to the corresponding wires in your vehicle.

Step-by-Step Instructions:

1. Disconnect the Battery:

   • Before beginning, disconnect the battery terminals to prevent electrical shorts or damage.

2. Connect the Wires:

   • Refer to the following chart to match the harness wires to their functions:
     • Black Wire: Battery Positive (+)
     • Red Wire: Stoplight Signal (active when the brake pedal is pressed)
     • White Wire: Ground (-)
     • Blue Wire: Output to Trailer Brakes
   • Use the appropriate connectors to secure each wire, ensuring a solid connection.

3. Secure the Wiring Harness:

   • Mount the wiring harness under the dashboard or another safe location, keeping it away from moving parts or sharp edges.

4. Plug in the Brake Controller:

   • Insert the wiring harness connector into the brake controller, ensuring it clicks securely into place.

5. Reconnect the Battery:

   • Reattach the battery terminals, ensuring they are clean and tightly connected.

6. Test the System:

   • Use a test light, circuit tester, or trailer to verify all functions:
     • The brake controller powers on.
     • The manual override activates the trailer brakes.
     • Stoplight signals and trailer brakes function properly when the brake pedal is pressed.

Notes:

• Always connect wires based on function, not color, to ensure proper operation.
• Consult your vehicle manual for fuse locations related to the brake control system.
• Verify all connections are secure and tested before use.

Warning:

• All connections must be complete for the system to function properly.
• Overloading circuits can cause damage or fire. Do not exceed the lower of the towing manufacturer’s ratings or:
  • Max. Right Turn, Left Turn, Stop, & Tail Light Circuits: 7.5 amps
  • Max. (+) Battery, Reverse, and Electric Brake Circuits: 30 amps
• Refer to your vehicle’s owner’s manual for additional instructions. Additional fusing may be required.

For safe towing and optimal performance, ensure all connections are properly secured and tested.

Installation and Operation Instructions for Voyager Electronic Brake Control

Specifications:

• Compatible with 2, 4, 6, and 8 brake applications.
• Uses an inertial sensor for proportional braking.

Tools Required:

• Drill with a 1/8” bit.

• 6 x 3/8” screws.

• Screwdriver or wrench.

Safety Notes:

1. Avoid mounting or operating RF-generating devices (e.g., cell phones, two-way radios) closer than 12 inches to the brake control.
2. Reversing the connection to a breakaway battery will damage the brake control.
3. Disconnect the trailer plug before testing a breakaway switch to prevent damage.
4. The level adjustment is critical for proper braking response.
5. Always adhere to the vehicle's Gross Combined Weight Rating (GCWR).
6. This unit is designed for electric trailer brakes only.

Hardware List:

• Voyager brake control unit.
• Mounting bracket.
• Screws for mounting.

Installation Instructions:

Mounting the Brake Control:

1. Select a Mounting Location:
   • Ensure a flat, solid surface between -20° nose down and 70° nose up.
   • Avoid any area with potential interference or unstable mounting.
2. Attach the Mounting Bracket:
   • Use the provided #6 x 3/8” screws to securely mount the bracket.
   • Avoid over-tightening or using longer screws to prevent damage.
3. Install the Brake Control:
   • Attach the control to the bracket and adjust its position.
   • Tighten the screws snugly to secure the unit.

Leveling the Sensor:

1. Connect the trailer to the tow vehicle. The bi-colored light should glow green.
2. Turn the Power Knob to maximum (clockwise).
3. Press and hold the brake pedal.
4. Adjust the Level Knob:
   • Turn it counter-clockwise until the light changes from green to red.
   • Slowly turn it clockwise until an orange light is visible.
   • Light Settings:
     • Dim orange: Normal setting.
     • Bright orange: Aggressive braking.
     • Dim red: More aggressive braking.

Adjusting Power to Trailer Brakes:

1. Connect the trailer to the tow vehicle.
2. Turn the Power Knob to the 12 o’clock position.
3. Drive at 25 mph on a dry, level surface.
4. Apply the Manual Slide Knob:
   • If trailer brakes lock up, decrease power (turn counter-clockwise).
   • If braking is insufficient, increase power (turn clockwise).
5. Repeat until the braking is smooth and sufficient without wheel lock-up.

Fine-Tuning:

1. Make several slow stops to assess braking response.
   • If brakes grab too much, reduce aggressiveness by turning the Level Knob clockwise.
   • If braking is delayed, increase aggressiveness by turning the Level Knob counter-clockwise.

Maintenance:

• Regularly inspect connections and ensure wires are secure.
• Adjust brakes after the first 200 miles of use and every 3,000 miles thereafter.
• Keep the unit clean and free from debris.

Troubleshooting Guide:

Warranty Information:

• Limited Warranty:
  • Covers defects in materials and workmanship.
  • Excludes damage caused by improper installation, misuse, or external factors.
• Attention: This is a summary of the installation procedure. For complete installation instructions, including detailed diagrams and additional information, please download the full installation PDF.

For technical support and assistance, our team of experts is available to help. You can reach our tech support by visiting www.trailerjacks.com or calling 877-869-6690.