The Tekonsha Voyager is a state-of-the-art electronic brake controller designed for safe and efficient trailer braking. With proportional braking technology, it ensures smooth and controlled deceleration, enhancing towing safety. Ideal for trailers with 2 to 8 brakes, it features a user-friendly interface and manual override functionality for optimal control. This guide provides detailed instructions for installation, setup, and operation, ensuring a secure and reliable towing experience.

1.1 Overview of the Tekonsha Voyager

The Tekonsha Voyager is an advanced electronic brake controller designed for trailers with 2, 4, 6, or 8 brakes. It features a proportional braking system, which automatically adjusts brake power based on the tow vehicle’s deceleration, ensuring smooth and controlled stopping. The unit includes a manual override function, an LED indicator for status monitoring, and a compact design for easy installation. This controller is ideal for towing enthusiasts seeking reliable and efficient trailer braking performance, with detailed setup and operation guidance provided in the user manual.

1.2 Key Features and Benefits

The Tekonsha Voyager offers a range of innovative features, including proportional braking for smooth deceleration, compatibility with 2-8 brake systems, and a manual override function for emergencies. Its compact design allows easy installation, while the LED indicator provides real-time status updates. The unit ensures consistent braking performance and enhances towing safety. Additionally, it supports trailers with 1-4 axles and comes with mounting hardware for hassle-free setup. These features make it a reliable choice for both novice and experienced tower operators, ensuring safe and efficient trailer braking control.

Safety Precautions and Warnings

Always read and follow instructions before installation or operation. Ensure proper mounting and periodic inspections of the brake control unit. Never operate without secure connections.

2.1 General Safety Guidelines

Safety is paramount when installing and operating the Tekonsha Voyager. Always read and follow the manual carefully before starting. Ensure the Brake Control Unit, LED Indicator, and Manual Knob Control Unit are securely mounted. Periodically inspect these components to confirm they are tightly fastened. Trailer brakes should be inspected every 3,000 miles or as needed. Keep this manual with the brake control for future reference and ensure all connections are secure before use.

2.2 Important Warnings Before Installation

Before installing the Tekonsha Voyager, ensure the vehicle and trailer are properly prepared. Never log off or forcibly exit the system during installation, as this may cause errors. Use only the correct software version provided by Tekonsha to avoid compatibility issues. Ensure the trailer brake system matches the controller’s specifications to prevent malfunctions. Always disconnect the battery before starting work to avoid electrical shocks. Consult the manual for specific wiring and mounting instructions to guarantee safe and proper installation.

Components of the Tekonsha Voyager

The Tekonsha Voyager consists of a Brake Control Unit, an LED Indicator, and a Manual Knob Control Unit. These components work together to provide precise trailer brake control and monitoring.

3.1 Brake Control Unit

The Brake Control Unit is the core component of the Tekonsha Voyager system, responsible for managing the trailer’s brakes proportionally. It features a compact design that mounts securely under the vehicle’s dashboard, ensuring ease of access. The unit includes a manual override function, allowing you to apply the trailer brakes independently of the tow vehicle’s brakes. Its advanced technology ensures smooth and precise braking, enhancing overall towing safety. The Brake Control Unit is designed to work seamlessly with the LED indicator for real-time monitoring of brake activity and system status.

3.2 LED Indicator

The LED Indicator on the Tekonsha Voyager provides visual feedback on the system’s status. Located on the front of the Brake Control Unit, it displays different colors to indicate various modes of operation. A steady GREEN light confirms the system is powered and ready for use, while a RED light signals active braking. Some models may also feature a BLUE light for additional status indicators or a flashing pattern to alert users of system faults or issues requiring attention. This feature ensures quick and easy monitoring of the brake control system’s functionality.

3.3 Manual Knob Control Unit

The Manual Knob Control Unit allows for precise adjustment of the trailer brakes. Located on the front of the Brake Control Unit, it enables manual activation of the brakes for testing or emergencies. Turning the knob applies power to the trailer brakes proportionally, based on the knob’s position. This feature ensures quick and reliable control when needed. The manual override function is particularly useful for initial setup or troubleshooting, providing an additional layer of safety and control during towing operations. Proper use of the manual knob is essential for optimal braking performance.

Installation Instructions

Mount the Brake Control Unit securely, follow the wiring diagram, and connect the vehicle’s harness. Ensure all connections are correct for safe and efficient trailer braking.

4.1 Pre-Installation Checklist

Before installing the Tekonsha Voyager, ensure your vehicle and trailer are compatible. Read the manual thoroughly, gather necessary tools, and confirm a 12V negative ground system. Inspect the trailer brakes and wiring for damage. Disconnect the vehicle’s battery to prevent electrical shocks. Verify all components, including the Brake Control Unit, LED indicator, and Manual Knob, are included. Plan the mounting location for optimal accessibility and stability during operation.

4.2 Mounting the Brake Control Unit

Mount the Brake Control Unit securely in an accessible location, ideally under the dashboard. Use the provided mounting hardware to fasten it firmly to the vehicle. Ensure the unit is level and protected from moisture or extreme temperatures. Avoid locations near heating vents or direct sunlight. Connect the wiring harness carefully. Verify all connections are secure. Once mounted, test the unit to ensure proper function. Ensure the Manual Control is easily accessible for emergency braking situations.

4.3 Wiring Diagram and Connections

Refer to the provided wiring diagram for precise connections. Locate the vehicle’s electric brake control harness connector, typically under the dash and left of the steering column. Connect the black wire to the positive battery terminal, the blue wire to the brake pedal switch, and the white wire to the vehicle’s ground. Ensure all connections are secure and protected from moisture. Double-check the wiring to prevent errors. If unsure, consult a professional or the manual for detailed guidance to ensure safe and proper installation.

Adjusting the Brake Control

Adjust the Power Knob to fine-tune brake power based on trailer weight and driving conditions. Use the Manual Override to test or apply brakes independently. Ensure proper leveling for accurate proportional braking response.

5.1 Leveling the Sensor

Proper leveling of the Tekonsha Voyager sensor is crucial for accurate proportional braking. Mount the unit in a location where it remains level during normal driving conditions. Use a bubble level to ensure the sensor is perfectly horizontal. If the vehicle is equipped with air suspension, adjust the sensor after the suspension has stabilized. Improper leveling can lead to inconsistent brake performance. Refer to the manual for specific calibration steps to ensure optimal functionality and safety while towing. Regular checks are recommended to maintain precise control.

5.2 Setting the Power Knob

Set the Power Knob to the 12 o’clock position initially for balanced braking. This knob adjusts the maximum trailer brake power output, ensuring proportional braking relative to the tow vehicle’s deceleration. Turn the knob clockwise to increase brake power for heavier loads or clockwise for lighter setups. Fine-tune the setting during test drives to achieve smooth, consistent braking performance. The LED indicator will reflect the current power level, aiding in precise adjustments. Always test braking functionality after adjusting the Power Knob to ensure safe and reliable operation.

5.3 Manual Override Function

The Manual Override Function allows you to apply the trailer brakes independently of the tow vehicle’s brakes. Press and hold the Manual Knob to activate this feature, which is useful for testing or emergency situations. The LED indicator will turn red when the override is active. Release the knob to return to proportional braking. Use this function sparingly to avoid excessive wear on the trailer brakes. Always ensure the trailer brakes are functioning correctly after using the manual override.

Understanding the LED Indicators

The LED indicators provide visual feedback on the system’s status, showing connection, braking activity, and alerts. Different colors and patterns indicate various states, helping monitor and diagnose issues effectively.

6.1 LED Color Codes and Meanings

The LED indicators on the Tekonsha Voyager use specific color codes to communicate system status. A steady GREEN light indicates proper connection and operation, while a flashing GREEN suggests a system check. When the brake pedal is pressed, the light turns RED, showing active braking. A flashing RED signals an error or disconnection. Additional colors or patterns may indicate specific issues, such as power-level adjustments or system malfunctions, helping users quickly identify and address problems.

6.2 Troubleshooting LED Patterns

Use the LED indicators to diagnose issues with the Tekonsha Voyager. If the RED light flashes rapidly, it may indicate a disconnected trailer or faulty wiring. A steady RED light signals active braking. If the GREEN light flickers irregularly, check the trailer connection or battery voltage. For persistent issues, refer to the troubleshooting guide in the manual or reset the unit by cycling the power. Ensure all connections are secure and the sensor is properly leveled for accurate operation. Consult the manual or contact Tekonsha support for unresolved problems.

Maintenance and Inspection

Regularly inspect the Brake Control Unit, LED indicator, and connections for wear or damage. Clean dust and debris from components and ensure all mounts are secure. Periodic checks ensure optimal performance and safety while towing.

7.1 Periodic Inspection Checklist

Regular inspections are crucial for optimal performance. Check the Brake Control Unit for secure mounting and damage. Inspect the LED indicator for proper function and clean any debris. Verify all wiring connections are tight and free from corrosion. Ensure the Manual Knob Control Unit operates smoothly. Test the trailer brakes for responsiveness and adjust if necessary. Clean all components periodically to prevent dust buildup. Ensure the system is properly leveled and calibrated. Schedule inspections every 3,000 miles or as usage dictates.

7.2 Cleaning and Upkeep Tips

Regular cleaning ensures optimal performance. Use a soft cloth to wipe the LED indicator and Manual Knob Control Unit, removing dirt or debris. Avoid harsh chemicals, as they may damage components. Inspect and clean wiring connections to prevent corrosion; Lubricate moving parts periodically to maintain smooth operation. Store the manual in a dry place for future reference. Perform these tasks during routine inspections to ensure reliability and extend the lifespan of your Tekonsha Voyager brake control system.

Troubleshooting Common Issues

Troubleshoot common issues like error codes, wiring problems, or brake activation failures. Refer to the LED indicator for diagnostic patterns and consult the manual for solutions.