Installation Instructions for Voyager Electronic Brake Control

Part Number:

• N78081

Components Included:

• (1) Brake Control Unit
• (1) Mounting Bracket
• (2) #6 x 3/8" Mounting Screws
• (1) Installation Manual

Tools Required:

• Drill with 1/8" Bit
• Screwdriver
• Wire Crimpers
• Wire Strippers
• Probe-Type Circuit Tester
• Cable Ties

Step-by-Step Installation Instructions:

Step 1: Choose a Suitable Mounting Location

• Mount the brake control in a location where the driver can easily access it without obstructing visibility or movement.
• Ensure the mounting surface is solid and free of obstructions behind it.

Step 2: Mount the Bracket

1. Position the mounting bracket on the chosen surface and mark the hole locations.
2. Drill 1/8” pilot holes at the marked locations.
3. Secure the bracket using the provided #6 x 3/8" screws. Do not overtighten.

Step 3: Install the Brake Control Unit

1. Slide the brake control into the mounting bracket.
2. Secure the unit in place using the adjustment screws on the bracket. Ensure the unit is level with the direction of travel and within the recommended mounting angles:
   • -20° (nose down) to +70° (nose up).

Wiring Instructions:

Wiring Connections

• Black Wire: Vehicle Power
• White Wire: Vehicle Ground
• Red Wire: Stoplight Switch (activated by brake pedal)
• Blue Wire: Trailer Brakes

Wiring Process

1. Locate the vehicle’s stoplight switch wire using a circuit tester.
2. Connect the wires using appropriate crimp connectors or butt connectors:
   • Black wire to vehicle’s positive power source.
   • White wire to vehicle ground.
   • Red wire to the stoplight switch output.
   • Blue wire to the trailer brake output circuit.
3. Secure all wiring using cable ties to prevent loose or dangling connections.

Adjustments:

Step 1: Level the Sensor

1. Connect the trailer to the tow vehicle.
2. Ensure the bi-colored LED glows green, indicating a trailer connection.
3. Turn the power knob fully clockwise to maximum.
4. Depress the vehicle brake pedal.
5. Rotate the level knob counter-clockwise until the LED changes from green to red.
6. Slowly rotate the knob clockwise until the LED glows orange:
   • Dim Orange: Typical Setting
   • Bright Orange: Aggressive Setting
   • Dim Red: More Aggressive Setting
7. Release the brake pedal.

Step 2: Adjust the Power

1. Set the power knob to the 12 o’clock position.
2. Drive the vehicle and trailer on a dry, level surface at 25 mph.
3. Apply the manual slide knob to test the trailer brakes:
   • If the trailer brakes lock up, reduce the power by rotating the knob counter-clockwise.
   • If braking is insufficient, increase the power by rotating the knob clockwise.
4. Repeat until the braking force provides maximum braking without wheel lockup.

Fine Tuning:

• Perform slow stops at 25 mph and adjust the level knob to achieve the desired braking response:
  • Rotate the level knob clockwise to reduce braking aggression.
  • Rotate counter-clockwise to reduce delay in braking.

Maintenance:

• Regularly inspect all connections for wear or corrosion.
• Verify that the mounting screws remain tight.
• Test the brake control before each use to ensure proper function.

Troubleshooting:

LED Indicators:

• Green: Trailer connected.
• Red: Brake pedal or manual control activated.
• Flashing Red or Dim Red: Fault in the brake line or insufficient power.

Common Issues and Resolutions:

1. No LED Light:
   • Check power and ground connections.
   • Inspect trailer plug contacts for corrosion.
2. Brake Aggression Too High:
   • Adjust level knob clockwise.
   • Reduce power setting.
3. Delayed Braking Response:
   • Adjust level knob counter-clockwise.
   • Increase power setting.

Safety Notes:

• Do not mount or operate RF-emitting devices (e.g., cell phones, two-way radios) within 12 inches of the brake control.
• Disconnect the trailer plug before testing the breakaway switch to avoid damage to the control.
• Ensure that the combined weight of the trailer and vehicle does not exceed the manufacturer’s Gross Combined Weight Rating (GCWR).

Specifications:

• Brake Applications: 2, 4, 6, and 8 Brakes
• Voltage Requirements: 12V DC
• Mounting Angle Range: -20° to +70°

Installation Instructions for 7-Way Trailer Tow Harness

Part Number:

• N78071

Tools Required:

• Drill with 1/4” and 3/32” Drill Bits
• 2” Hole Saw
• 5/16” Socket
• Center Punch
• Rust-Proof Coating (Not Provided)

Safety Warnings:

• Verify Surface Before Drilling: Check behind surfaces to avoid damage to the vehicle or personal injury.
• Avoid Hot Components: Route wiring carefully to avoid hot pipes, heat shields, the fuel tank, or any moving parts.
• Secure All Wiring: Loose wiring may cause damage or malfunction.
• Wear safety glasses and use all safety precautions during installation.

Installation Steps:

Step 1: Determine Mounting Location

• Locate a suitable mounting point on the tow vehicle, typically on the driver’s side between the rear cab post and the wheel well.
• Ensure the selected mounting location has sufficient clearance for the adapter.

Step 2: Drill the Mounting Hole

• Drill a 1/4” pilot hole in the chosen location using a center punch to mark the spot.
• Recheck your mounting location and wire lengths.
• Use a 2” hole saw to finish cutting the mounting hole.

CAUTION

• Verify what is behind the surface before drilling to avoid damage.
• If the vehicle has a bedliner, notch the liner or use longer screws to mount directly through the liner into the body panel.
• Apply rust-proof coating to drilled areas to prevent rusting.

Step 3: Route the Wire Connectors

• Route the factory wire connectors (OE connectors) carefully through the 2” hole.
• Avoid scraping or damaging the wires against the sharp edges of the drilled hole.

Step 4: Mount the 7-Way Plug

• Use the 7-Way plug as a guide to mark the mounting holes with a center punch.
• Slide the 7-Way plug back and drill four 3/32” holes at the marked locations.
• Mount the 7-Way plug using the (4) provided self-tapping screws.

NOTE

• If the 90-degree corner of the 7-Way plug is too close to the outside wall of the truck bed, use the included spacer between the plug and the vehicle surface.

Step 5: Connect the 7-Way Harness

• Locate the vehicle’s 7-Way factory harness near or on the rear bumper.
• Carefully disconnect the factory connector, ensuring the locking tabs are not damaged.
• Connect the Trailer Tow Harness between the mating plugs.

NOTE

• On Dodge vehicles, the factory connector is rectangular.
• All connections must be fully seated for proper functionality.

Step 6: Verify Connections and Test

• Test the harness with a trailer or test light to confirm proper functionality. Ensure all connections are complete and secure.

NOTE

• Some vehicles may require the addition of a fuse or relay (not included) to activate all 7-Way functions. Refer to your vehicle's owner manual for the fuse or relay location.

Step 7: Secure the Wiring

• Route all wiring away from hot pipes, sharp edges, and moving parts.
• Secure all loose wires using cable ties or similar methods to prevent pinching or damage.

Maintenance:

• Periodically inspect all wiring connections for signs of wear, corrosion, or damage.
• Reapply rust-proof coating to drilled areas as necessary to maintain long-term protection.

Important Notes:

• Proper installation of the 7-Way harness is required to ensure trailer lighting, braking, and other functions operate correctly.
• Always test the trailer connections before towing to confirm safe and proper operation.

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.

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:

The product comes with a [X]-year warranty that covers defects in materials and workmanship. For complete warranty instructions, please download the full installation PDF.