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 Electronic Brake Control

Part Numbers:

• Included Brake Control Unit: Part Number N8507120

Tools Required:

• Drill with 1/8" bit.
• Screwdriver or 1/4" nut driver.
• Wire connector crimp tool.
• Probe-type circuit tester.
• Assorted end wrenches.
• Wire cutter/stripper.

Safety Notes:

• Ensure the area behind the panel is clear before drilling.
• Follow all instructions to prevent damage to the unit or injury during installation.
• Avoid using RF-generating devices closer than 12 inches to the brake control.
• Always verify proper electrical connections.

Hardware List:

• Brake Control Unit.
• Mounting Bracket.
• (4) Mounting Screws.
• Additional Materials Required:
  • 10 Ga. wire.
  • 30 Amp auto-reset circuit breaker.
  • Assorted ring terminal & butt connectors.
  • 4" cable ties (6-10).

Installation Instructions:

Mounting the Unit:

1. Choose a Suitable Location:
   • Ensure a secure, solid surface.
   • Ensure the unit is within easy reach of the driver.
   • Verify the area behind the panel is clear.
2. Mark and Drill Holes:
   • Use the bracket as a template to mark hole locations.
   • Drill two 1/8" diameter holes.
3. Attach the Bracket:
   • Secure the bracket using two self-tapping screws provided.
   • Avoid over-tightening to prevent damage to the holes.
4. Mount the Brake Control Unit:
   • Attach the control unit to the bracket with the remaining screws.

Wiring and Connections:

• Black Wire: Connect to the vehicle's power supply.
• Red Wire: Connect to the stoplight signal.
• White Wire: Connect to the vehicle's ground.
• Blue Wire: Connect to the trailer brakes.

Initial Setup:

1. With the trailer connected, press and hold the brake pedal.
2. Adjust the Output (Gain) Control to approximately 2.0 using the digital display.
3. Adjust the Sync Control to a setting of 4°.
4. Test the brake application by driving in an open area and using the manual slide control.

Sync and Output (Gain) Adjustments:

• Sync Control: Adjust the aggressiveness of trailer braking.
  • Sync settings range from 0° (least aggressive) to 9° (most aggressive).
• Output (Gain) Control: Adjust the maximum power delivered to the brakes.
  • Output ranges from 0 to 10, with 10 being maximum braking power.

Testing and Fine-Tuning:

1. Conduct a test drive at low speeds in a clear area.
2. Use the Manual Slide Control to apply trailer brakes and adjust the Gain as needed.
3. Verify smooth stops without jerking or locking the brakes.
4. Adjust Sync settings for road conditions and driver preferences.

Maintenance:

• Regularly inspect all connections and wires for damage or wear.
• Keep the unit clean and free of debris.
• Periodically check and tighten all mounting screws.

Troubleshooting Guide:

Warranty Information:

• Limited Lifetime Warranty:
  • Covers defects in materials and workmanship.
  • Excludes damage caused by misuse or improper installation.
• For complete warranty instructions, please download the full installation PDF.

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.

Attention: This is a summary of the installation procedure. For complete installation instructions, including diagrams and detailed information from the manufacturer, please download the full installation PDF.