Welcome to the Tekonsha Voyager Brake Controller instruction manual! This guide provides essential information for installing, operating, and maintaining your brake controller. Please read it carefully to ensure proper function and safety. This manual includes wiring diagrams, troubleshooting tips, and important safety precautions.

Key Features and Specifications

The Tekonsha Voyager brake controller is designed for trailers with 1 to 4 axles. This controller is known for its easy installation and reliable performance. Its key features include real-time diagnostics, providing you with immediate feedback on your trailer’s braking system. The Voyager boasts a compact design, allowing for flexible mounting options within your vehicle.

Key Features:

• Suitable for 1-4 Axle Trailers
• Easy Installation Process
• Real-Time Diagnostic Monitoring
• Compact and Versatile Design

Specifications:

• Brand: Tekonsha
• Color: Black
• Mounting Location: Dash
• Braking Type: Proportional

The Voyager utilizes solid-state electronics, ensuring durability and resistance to vibration. Its proportional braking system provides smooth and controlled stops. Mounting hardware is included for a straightforward installation process. The black finish ensures it blends seamlessly with most vehicle interiors. The controller provides a user-friendly interface, making adjustments simple.

Wiring Diagram and Connections

Proper wiring is crucial for the Tekonsha Voyager to function correctly. The standard wiring configuration involves four wires: white, black, blue, and red. The white wire must be connected to a reliable ground, ideally the negative post of the vehicle’s battery. The black wire connects to the positive post of the battery, providing power to the controller.

The blue wire runs to the trailer’s electric brake wire, carrying the braking signal. The red wire connects to the vehicle’s stoplight switch, activating the trailer brakes when the vehicle’s brakes are applied. Always ensure connections are secure and protected from corrosion. Using proper crimping tools and connectors is highly recommended for reliable connections.

Refer to the specific wiring diagram included with your Voyager for detailed instructions and vehicle-specific adaptations. Incorrect wiring can lead to controller malfunction or damage to your vehicle’s electrical system. Double-check all connections before operating the system. A hard-wiring diagram is also typically available for advanced installations.

Installation Procedure

Begin the installation by selecting a suitable mounting location for the Tekonsha Voyager. Ensure the location allows for easy access to the manual control and visibility of the display. Disconnect the vehicle’s battery before starting any wiring. Route the four wires (white, black, blue, and red) from the chosen mounting location to their respective connection points.

Connect the white wire to a solid ground, preferably the negative battery terminal. Connect the black wire to a 12V power source, ideally the positive battery terminal, with an inline fuse for protection. Connect the blue wire to the trailer brake wire, usually found at the trailer connector. Connect the red wire to the vehicle’s stoplight switch wire.

Secure all wiring with zip ties or electrical tape, ensuring no wires are pinched or exposed to sharp edges. Reconnect the vehicle’s battery and test the brake controller. Follow the initial setup and calibration procedures outlined in this manual to ensure proper functionality. Consult the troubleshooting guide if any issues arise during installation or testing.

Mounting Instructions

Proper mounting of the Tekonsha Voyager is crucial for optimal performance and safety. Select a location on your vehicle’s dash that is easily accessible and provides a clear view of the controller’s display. The controller should be mounted in a position that allows for convenient use of the manual control lever.

Use the provided mounting bracket to secure the controller to the dash. Ensure the bracket is firmly attached using screws or other appropriate fasteners. The controller should be mounted horizontally, aligned with the direction of travel, for the most accurate braking performance. Avoid mounting the controller near any RF-generating devices, such as cell phones or two-way radios.

Before finalizing the mounting location, check for any obstructions, such as airbags or other vehicle components. Make sure the wiring harness can be easily connected to the controller without putting excessive strain on the wires. Once you are satisfied with the location, securely fasten the controller to the mounting bracket. Double-check the mounting stability before proceeding with the wiring and calibration steps.

Manual Control Operation

The Tekonsha Voyager features a manual control lever that allows you to apply the trailer brakes independently of the vehicle’s brakes. This is particularly useful in situations requiring controlled braking or when testing the trailer brake functionality. The manual control is located on the front of the brake controller, typically on the right side.

To activate the manual control, gently slide the lever to the left. The further you slide the lever, the more braking force will be applied to the trailer brakes. Use the manual control sparingly and only when necessary. Avoid applying the trailer brakes too abruptly, as this could cause the trailer to sway or skid.

The manual control is also helpful for diagnosing trailer brake issues. By slowly applying the manual control, you can listen for any unusual noises or feel for any vibrations that may indicate a problem with the trailer brakes. Remember that the manual control only activates the trailer brakes and does not affect the vehicle’s brakes. Always exercise caution when using the manual control and be aware of your surroundings. Practice using the manual control in a safe, controlled environment before using it on the road.

Initial Setup and Calibration

Proper initial setup and calibration are crucial for optimal performance of your Tekonsha Voyager brake controller. Before hitting the road, ensure the controller is correctly calibrated to match your towing vehicle and trailer. This process involves adjusting the output level to provide sufficient braking power without causing trailer sway or lockup.

Begin by connecting your trailer to the towing vehicle, ensuring all electrical connections are secure. Start the vehicle and allow the brake controller to power on. The Voyager typically has a gain or power adjustment knob. Start with a low setting, around 4 or 5, and gradually increase it during a test drive.

Find a safe, open area to conduct your calibration. Drive at a moderate speed (around 20-25 mph) and apply the manual control lever on the brake controller. Observe the trailer’s braking response. If the trailer brakes lock up, reduce the gain setting. If you don’t feel sufficient braking, increase the gain. The goal is to achieve firm, smooth braking without lockup. After the test, adjust the settings and test again until you achieve optimal braking performance.

Troubleshooting Guide

Encountering issues with your Tekonsha Voyager? This troubleshooting guide addresses common problems. If your brake controller displays “OL” or no output, check your wiring connections, ensuring they are secure and properly grounded. A loose ground wire is a frequent culprit. Inspect the trailer’s electrical connector for corrosion or damage;

If the trailer brakes lock up excessively, reduce the gain setting on the controller. Conversely, if you experience weak braking, increase the gain. Ensure the brake controller is mounted securely and is not near any radio frequency generating devices, as these can interfere with its operation.

For intermittent braking issues, inspect the brake magnets on the trailer axles. Worn or damaged magnets can cause inconsistent braking. Use a multimeter to test the continuity of the brake wiring, both on the towing vehicle and the trailer. Consult a qualified technician for assistance, if needed. If problems persist, refer to the wiring diagram and recheck all connections.

Remember to consult the complete manual for more detailed solutions and diagrams.

Safety Precautions

Prioritize safety when operating the Tekonsha Voyager brake controller. Before each trip, inspect all wiring connections to ensure they are secure and free from corrosion. Verify the brake controller is firmly mounted and does not obstruct the driver’s view or interfere with vehicle controls. Never mount the controller near radio frequency generating devices, such as cell phones or two-way radios, as interference can occur.

Always test the trailer brakes manually before beginning your journey. Use the manual override lever to confirm the trailer brakes engage smoothly and proportionally. Be aware of local traffic laws and regulations regarding trailer braking systems. Ensure your trailer’s braking system is compatible with the Tekonsha Voyager.

If you notice any unusual behavior, such as excessive brake lockup or weak braking, stop immediately and investigate the issue. Do not attempt to operate the trailer with a malfunctioning brake controller. Consult a qualified technician if you are unsure about any aspect of the brake controller’s operation. Remember, safety is paramount when towing a trailer. Always prioritize responsible driving practices.

Maintenance and Care

To ensure the longevity and reliable performance of your Tekonsha Voyager brake controller, regular maintenance and care are essential. Periodically inspect all wiring connections for corrosion, looseness, or damage. Clean any corroded connections with a wire brush and apply dielectric grease to prevent future corrosion. Check the mounting hardware to ensure the controller remains securely fastened.

Keep the brake controller clean and free from dust and debris. Use a soft, damp cloth to wipe down the exterior. Avoid using harsh chemicals or abrasive cleaners, as these can damage the controller’s finish. When the brake controller is not in use, store it in a dry, protected environment.

If you experience any issues with the brake controller’s performance, consult the troubleshooting guide in this manual. If the problem persists, contact a qualified technician for assistance. Do not attempt to disassemble or repair the brake controller yourself, as this may void the warranty and could cause further damage. Proper maintenance and care will help ensure your Tekonsha Voyager brake controller provides years of reliable service.