®

VOYAGER ELECTRONIC BRAKE CONTROL

Instructions for Voyager® Brake Control
For 2, 4, 6* and 8* brake applications Installation Guide Leveling the Sensor
READ THIS FIRST: WARNING The Brake Control must be After the brake control has been securely mounted
mounted from -20 degrees nose down to 70 the level adjustment must be set.
Read and follow all instructions carefully
before installing or operating the Brake degrees nose up. (See Below.) Failure to install
Control. Keep these instructions with the brake control within these constraints may NOTE:
Brake Control for future reference. cause your control to become inoperable. 1. WARNING This brake control is
activated by inertia and requires the
70° level to be set properly, or the braking
Components of the Brake Control response will be too harsh or ineffective.
2. To properly level the sensor, the trailer
and tow vehicle must be parked on
D a level surface and trailer must be
connected to tow vehicle.
E A
1. Connect trailer to tow vehicle, Bi-Colored
Light should glow GREEN.
B 0°
C 2. Set power knob to maximum by fully
rotating clockwise.
3. Depress tow vehicle’s brake pedal and hold.
-20° 4. Rotate the Level Knob counter-clockwise
(towards the back of the control) until the
A. Power Knob
Traditional Bracket Mount Bi-Colored Light starts to change colors
from GREEN to RED.
B. Manual Slide Knob A B 5. Carefully rotate the Level Knob clockwise
C. Bracket Mounting Holes (towards the front of the control) until
D. Bi-Colored Light a shade of ORANGE is visible.
E. Level Knob
Bi-Colored Light should show:
Important Facts to Remember • DIM ORANGE for a typical setting.
1. Do not mount or activate RF generating items A. Mounting Bracket • BRIGHT ORANGE for an aggressive setting.
(cell phones, two way radios) near (less than B. #6 x 3/8” Screws • DIM RED for a more aggressive setting.
12") the Brake Control.
2. CAUTION Reversing the connection to a
1. CAUTION Drilling or use of longer NOTE: Range of adjustment for the level
screws may damage unit. knob from DIM ORANGE to DIM RED
breakaway battery on the trailer will destroy
2. Securely mount bracket to a solid surface. is 20 degrees of rotation.
the Brake Control.
3. Insert supplied #6 x 3/8” screws on each
3. CAUTION Disconnect trailer plug from the 6. Release brake pedal.
side into the mounting holes.
tow vehicle prior to testing a breakaway
switch or you may destroy the Brake Control. 4. Adjust control to desired position and NOTE: When the brake control is leveled
tighten screws until snug. properly there will be very little current
4. The light is:
flowing through the brake magnets in a
• GREEN when trailer is connected. static state with the foot pedal depressed.
• RED when brake pedal or manual is NOTE: The brake magnets will hum when there is
activated and trailer is connected. 1. Front of the Voyager must be horizontal,
current flowing through them. Anytime the
5. The GREEN light draws 5 milliamperes of see below.
Bi-Colored Light shows any color other than
current from tow vehicle. It would take over 2. The Voyager must be parallel to direction
GREEN, there is current flowing through
10,000 hours to drain the tow vehicle battery. of travel, see below.
the brake magnets.
6. WARNING The level adjustment is
CRITICAL. The level adjustment Correct Incorrect Adjusting the Power to the
determines whether automatic braking
response is delayed or aggressive.
Trailer Brakes
Once the control has been installed and properly
7. This brake control is activated by inertia.
leveled, it is necessary to set the power needed
It senses deceleration and generates an
to stop the trailer during a braking event.
output that reflects the inertia sensed.
In a stationary state, the brake control 1. Connect trailer to tow vehicle.
will not apply the trailer brakes unless 2. Set Power Knob to the 12 o’clock position.
the Manual Slide Knob is actuated. 3. Drive tow vehicle and trailer on a dry level
8. WARNING The Gross Combined Weight paved surface at 25 mph and apply manual
Rating (GCWR) must never exceed the slide knob.
vehicle manufacturers recommendation. ✓ If trailer brakes lock up:
9. This control specfically designed for use ❑ Turn power down using power knob.
with electric trailer brakes. (Rotate power knob toward the 8 o’clock
10. For Technical Assistance and Warranty position, counter-clockwise.)
Information call: 1-888-785-5832 or ✓ If braking was not sufficient:
www.tekonsha.com D i r e c t i o n o f Tr ave l D i r e c t i o n o f Tr ave l
❑ Turn power up using power knob.
(Rotate power knob toward the 5 o’clock
position, clockwise.)

Technical Assistance Call Toll-Free: 1-888-785-5832 or www.tekonsha.com P/N 3840 REV J 08/03
1
 ®

VOYAGER ELECTRONIC BRAKE CONTROL

Instructions for Voyager® Brake Control (CONTINUED)
4. Repeat Step (3) until power has been set
to a point just below wheel lock up or at NOTE:
1. Always warm the trailer's brakes before 4. Not all trailer brakes will lock up due to
a sufficient force as to achieve maximum
setting the power. Warm trailer brakes tend to various conditions. However, inability to lock
braking power.
be more responsive than cold brakes. To warm up the brakes generally indicates the need for
5. Using the brake pedal, make a few low trailer brakes, drive a short distance (1/4 mile) an inspection to determine the cause.
speed stops to check the Power and Level at 45 MPH with manual lever engaged enough 5. When the power is set correctly you should
adjustments. The automatic response to cause trailer braking at a low level. feel unified braking between the trailer and
(brake pedal) is initiated and terminated tow vehicle.
2. WARNING The power should never be set
via the stoplight switch. When the brake 6. When in doubt of the proper setting procedures
high enough to cause trailer brakes to lock up.
pedal is released, trailer braking will cease. review the above steps starting at LEVELING
Skidding trailer wheels can cause loss of
Fine Tuning directional stability of trailer and tow vehicle. THE SENSOR through FINE TUNING or
3. The power may need to be adjusted for consult your tow card included with your
Now that the Power has been set, it is time
different load weights and road conditions. brake control.
to fine tune the level setting for the majority
of the stopping that you will be doing.
1. Make several slow (25 MPH) stops as Troubleshooting Chart
if coming up to a stop sign and take
notice of how the trailer brakes respond: Situation Probable Cause
✓ Brakes Grab Too Much
❑ You have an Aggressive Setting: Tow vehicle connected to trailer, 1. Corrosion on trailer plug contact.
To correct this condition rotate level NO GREEN light. 2. Loose POWER or GROUND connection.
knob clockwise, toward you, see below.
Tow vehicle connected to trailer, light is
✓ Trailer Tending to Push Tow Vehicle GREEN. When Manual Slide Knob is activated:
❑ You have a Delayed Setting: A. No RED light. 1. POWER set at or near minimum.
To correct this condition rotate level 2. Short on BRAKE line (BLUE wire).
knob counter-clockwise, away from 3. BLACK & WHITE wires reversed,
you, see below. control destroyed.
2. Repeat until desired trailer braking 4. 12 volts from external source on BRAKE
is achieved. line (BLUE wire).
B. Light is dim RED or flashing RED. 1. Open on GROUND line (WHITE wire).
2. Short on BRAKE line (BLUE wire).
C. Light glows dim RED and gets brighter 1. Short on BRAKE line (BLUE wire).
as POWER Knob is decreased. 2. Defective brake magnets.
Braking with foot pedal is too aggressive. 1. Sensor set too aggressive,
B see LEVELING SENSOR.
2. Power set too high.
A C Braking is delayed for extended period. 1. Sensor set improperly,
A. Delayed see LEVELING SENSOR.
B. Normal 2. Power set too low.
C. Aggressive Tow vehicle connected to trailer, brake 1. Vehicle not moving, need to be moving
pedal depressed: for brakes to apply.
A. No RED light. 2. No signal from brake light, test voltage
on RED wire.
3. Sensor set improperly,
see LEVELING SENSOR.
4. Bad connection on RED wire.
5. Blown stoplight fuse.

Appendix A: Trailer Brake Adjustment**

Brakes should be adjusted after the first 200 miles of brake shoes. Adjust the brake shoes out until the
operation when the brake shoes and drums have “seated” pressure of the linings against the drum makes the
and at 3000 mile intervals, or as use and performance wheel very difficult to turn.
requires. The brakes should be adjusted in the Note: With drop spindle axles, a modified adjusting
following manner: tool with about an 80 degree angle should be used.
1. Jack up trailer and secure on adequate capacity 4. Then rotate the starwheel in the opposite direction
jack stands. Follow trailer manufacturers until the wheel turns freely with a slight lining drag.
recommendations for lifting and supporting the 5. Replace the adjusting hole cover and lower the
unit. Check that the wheel and drum rotate freely. wheel to the ground.
WARNING Do not lift or support trailer on any 6. Repeat the above procedure on all brakes.
part of the axle or the suspension system. WARNING Never crawl under your trailer unless
2. Remove the adjusting hole cover from the adjusting it is resting on properly placed jack stands.
slot on the bottom of the brake backing plate. Follow the trailer manufacturers recommendations
3. With a screwdriver or standard adjusting tool, rotate for lifting and supporting the unit. Do not lift or place
the starwheel of the adjuster assembly to expand the supports on any part of the suspension system.
**Note: Trailer Brake Adjustment procedures courtesy
Dexter Axle.

Technical Assistance Call Toll-Free: 1-888-785-5832 or www.tekonsha.com P/N 3840 REV J 08/03
2