Technical Assistance Call Toll-Free: 1-888-785-5832 or www.tekonsha.com
Instructions for Voyager
®
Brake Control
VOYAGER
®
ELECTRONIC BRAKE CONTROL
1
P/N 3840 REV J 08/03
For 2, 4, 6* and 8* brake applications
Components of the Brake Control
A. Power Knob
B. Manual Slide Knob
C. Bracket Mounting Holes
D. Bi-Colored Light
E. Level Knob
Important Facts to Remember
1. Do not mount or activate RF generating items
(cell phones, two way radios) near (less than
12") the Brake Control.
2. CAUTION Reversing the connection to a
breakaway battery on the trailer will destroy
the Brake Control.
3. CAUTION Disconnect trailer plug from the
tow vehicle prior to testing a breakaway
switch or you may destroy the Brake Control.
4. The light is:
• GREEN when trailer is connected.
• RED when brake pedal or manual is
activated and trailer is connected.
5. The GREEN light draws 5 milliamperes of
current from tow vehicle. It would take over
10,000 hours to drain the tow vehicle battery.
6. WARNING The level adjustment is
CRITICAL. The level adjustment
determines whether automatic braking
response is delayed or aggressive.
7. This brake control is activated by inertia.
It senses deceleration and generates an
output that reflects the inertia sensed.
In a stationary state, the brake control
will not apply the trailer brakes unless
the Manual Slide Knob is actuated.
8. WARNING The Gross Combined Weight
Rating (GCWR) must never exceed the
vehicle manufacturers recommendation.
9. This control specfically designed for use
with electric trailer brakes.
10. For Technical Assistance and Warranty
Information call: 1-888-785-5832 or
www.tekonsha.com
Installation Guide
WARNING The Brake Control must be
mounted from -20 degrees nose down to 70
degrees nose up. (See Below.) Failure to install
brake control within these constraints may
cause your control to become inoperable.
Traditional Bracket Mount
A. Mounting Bracket
B. #6 x 3/8” Screws
1.
CAUTION Drilling or use of longer
screws may damage unit.
2. Securely mount bracket to a solid surface.
3. Insert supplied #6 x 3/8” screws on each
side into the mounting holes.
4. Adjust control to desired position and
tighten screws until snug.
READ THIS FIRST:
Read and follow all instructions carefully
before installing or operating the Brake
Control. Keep these instructions with the
Brake Control for future reference.
D
E
B
A
-20°
0°
70°
A
B
C
Leveling the Sensor
After the brake control has been securely mounted
the level adjustment must be set.
1. Connect trailer to tow vehicle, Bi-Colored
Light should glow GREEN.
2. Set power knob to maximum by fully
rotating clockwise.
3. Depress tow vehicle’s brake pedal and hold.
4. Rotate the Level Knob counter-clockwise
(towards the back of the control) until the
Bi-Colored Light starts to change colors
from GREEN to RED.
5. Carefully rotate the Level Knob clockwise
(towards the front of the control) until
a shade of ORANGE is visible.
Bi-Colored Light should show:
• DIM ORANGE for a typical setting.
• BRIGHT ORANGE for an aggressive setting.
• DIM RED for a more aggressive setting.
6. Release brake pedal.
Adjusting the Power to the
Trailer Brakes
Once the control has been installed and properly
leveled, it is necessary to set the power needed
to stop the trailer during a braking event.
1. Connect trailer to tow vehicle.
2. Set Power Knob to the 12 o’clock position.
3. Drive tow vehicle and trailer on a dry level
paved surface at 25 mph and apply manual
slide knob.
✓ If trailer brakes lock up:
❑ Turn power down using power knob.
(Rotate power knob toward the 8 o’clock
position, counter-clockwise.)
✓ If braking was not sufficient:
❑ Turn power up using power knob.
(Rotate power knob toward the 5 o’clock
position, clockwise.)
NOTE: Range of adjustment for the level
knob from DIM ORANGE to DIM RED
is 20 degrees of rotation.
NOTE: When the brake control is leveled
properly there will be very little current
flowing through the brake magnets in a
static state with the foot pedal depressed.
The brake magnets will hum when there is
current flowing through them. Anytime the
Bi-Colored Light shows any color other than
GREEN, there is current flowing through
the brake magnets.
NOTE:
1. Front of the Voyager must be horizontal,
see below.
2. The Voyager must be parallel to direction
of travel, see below.
NOTE:
1. WARNING This brake control is
activated by inertia and requires the
level to be set properly, or the braking
response will be too harsh or ineffective.
2. To properly level the sensor, the trailer
and tow vehicle must be parked on
a level surface and trailer must be
connected to tow vehicle.
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