Troubleshooting Manual Override Causing Error Message on Brake Controller

Question:

So I just wired up a brake controller item # tk90160 with a 7 pin kit item # etbc7. Everything seems to be working great until I test the brake controller and use the manual override. Once pressed, I hear a click and see the brake controller flash SH said to be a brake wire short according to the instructions. Once this happens for about 3 seconds, the power goes out on the brake controller. This does not happen when pressing the brake pedal or anything else. I do not have a trailer connected, but this shouldnt be happening, right? The only part of the job that Im not 100 confident on is tapping into the cold side of the brake wire. I found it on the brake pedal wiring harness and tapped into it with the t connector, but could only reach with one hand and didnt have much wire outside of the sheathing to make it easy. Is this problem because of that connection? What can I do to fix this? Or is this all due to not having a trailer plugged in? I have to pick up a trailer Saturday and need this completed before I get it. Thank you, please let me know if you need more info. I can upload a picture of needed too.

asked by: David G

Expert Reply:

The brake controller error is not connected to the brake pedal. The short is either due to a poor ground connection or another issue with the power coming into the unit. It sounds like the circuit breaker is tripping (thus the click) when you use the manual override to send power to the 7-way. I recommend checking the connections at that breaker to ensure everything is grounded correctly to bare metal and that your wiring connections are good. You should have the 30 amp circuit breaker connected there for your brake controller.

expert reply by: Jason S