Troubleshooting Overload Output Message on Prodigy P3 Brake Controller

Question:

I have a 2004 Ford F-250 Super Duty and have this brake controller. It was fine for a while after installation but now it is reading Warning Output Shorted, No Brakes. I checked all the wiring and cant see any wires that are frayed or torn in any way to maybe be grounding out. I even bought a new plug and put it on and the unit is still saying the same thing. Is there something wrong with the actual unit?

asked by: Steve

Expert Reply:

The overload warning you are seeing indicates that the P3, # 90195, detects an excessive current overload condition during operation. This means that there is most likely a short in the brake output wire.

Check the trailer connectors inside and out for proper wiring and make sure there are no wires shorting to the brake output wires or connections. Also clean out any corrosion you may find in the trailer connectors.

If you do not find any corrosion in the trailer connectors, it is time to check out the trailer. Make sure the ground wire at the trailer tongue is grounded properly to a clean rust, paint and primer free portion of the trailer frame. Also, make sure one wire from each brake magnet is grounded properly either to the ground wire from the trailer connector or to the trailer frame.

Next, check the brake feed power wire all the way back to the brake magnet connections. If the wire is pinched frayed or broken and contacting the trailer frame or another wire, correct any of these issues.

If the solution to the problem is still not found, check the brake magnets themselves for wear. This will require removing the trailer hub and drum, and visually inspecting the trailer brake magnets. If you see the magnet windings coming through the face of the magnet or abnormal wear, the magnet is shorted and will need to be replaced.

expert reply by: Jameson C