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 Instructions for Electronic Brake Control

Product Information:

• Model: Electronic Brake Control for 2, 4, 6, & 8 Brake Applications
• Part Number: N8508220

Tools Required:

• Drill with 1/8" drill bit
• Screwdriver or 1/4" Nut Driver
• Wire Cutter/Stripper
• Wire Crimping Tool
• Probe-type Circuit Tester
• Assorted End Wrenches

Components Included:

• Brake Control Unit
• Mounting Bracket
• Mounting Screws (#6 x 3/8") (Qty: 4)
• Warranty Card

Mounting Instructions:

1. Select a Suitable Mounting Location:

   • Must be securely mounted to a solid surface.
   • Must be within easy reach of the driver.
   • Ensure the area behind the mounting location is clear before drilling.

2. Mark the Hole Locations:

   • Hold the mounting bracket in place.
   • Mark the holes using the slots in the bracket as a template.

3. Drill Mounting Holes:

   • Use a 1/8" drill bit to drill holes at the marked locations.

4. Secure the Bracket:

   • Use two self-tapping screws to secure the bracket.
   • Avoid over-tightening to prevent stripping the holes.

5. Mount the Brake Control Unit:

   • Secure the unit to the bracket using the remaining two screws.

Wiring Instructions:

1. Connect the Wires:

   • Black Wire: Vehicle Power (12V positive battery connection, use a 30A circuit breaker).
   • White Wire: Vehicle Ground (secure to a clean, bare metal surface).
   • Red Wire: Stop Light Switch (connect to the wire that activates only when the brake pedal is pressed).
   • Blue Wire: Trailer Brakes (connect to the brake wire at the trailer connector).

2. Verify Wiring Connections:

   • Use a circuit tester to confirm correct connections.

Controls and Operation:

1. Output (Gain) Control:

   • Adjusts the maximum power delivered to the trailer brakes.
   • Use the +/- buttons to increase or decrease output.
   • Display shows values from 0 to 10 (0 = minimum power, 10 = maximum power).

2. Manual Control:

   • Located on the front of the brake control unit.
   • Slide the control to manually apply the trailer brakes.
   • Use this feature to check or adjust brake performance.

3. Boost Control:

   • Provides more aggressive trailer braking.
   • Boost levels: b.1, b.2, and b.3.
   • Increase or decrease the boost by pressing the Boost Control button.

Setting Power to the Trailer Brakes:

1. Connect the trailer to the tow vehicle.
2. With the engine running, set the Output/Gain to approximately 5.0.
3. Drive at 25 mph on a dry, level surface.
4. Apply the Manual Control fully:
   • If trailer brakes lock up, decrease power.
   • If braking is insufficient, increase power.
5. Repeat until braking is smooth and effective, just below wheel lock-up.

Troubleshooting Guide:

Safety Notes:

• Do not mount the unit at an angle greater than -20° to +70° from level.
• Ensure all wiring connections are secure to avoid braking failures.
• Regularly inspect trailer brakes for wear and proper adjustment.

Technical Support:

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.

Warranty Information:

• Limited Warranty: Covers defects in materials and workmanship.
• Excludes misuse, improper installation, and normal wear and tear.

For complete warranty instructions, please download the full installation PDF.