Hopkins Agility Electric Brake Controller Powers On but Trailer Brakes Do Not Work
Question:
My unit is not displaying the percentage of braking on the LCD display. The red dot power indicator is lighted. The trailer brakes are not working. Ive tried manually operating the trailer brakes and that doesnt work either. This unit has operated properly since installation 1 year ago. Any suggestions?
asked by: Larry
Expert Reply:
You could have a loss of ground somewhere in the system. Since the brake controller is lighting up, it is probably not the brake controller ground. What you can do is sever the blue wire behind the controller and then apply the manual override on full. Test the severed blue wire with a circuit tester like # PTW2993 if needed. If no signal comes through, then the brake controller will need to be replaced.
If there is a signal, then you know the trouble is somewhere behind the brake controller on the truck or trailer. One quick note; make sure to engage the manual override on full and then let it snap back into place several times to clean the contacts. Dirty contacts may cause a problem as well.
If you have inadvertently bumped the controller, it may have knocked it out of proper alignment. You can use the instructions I have linked for you to reset and mount the brake controller and see if that helps.
If everything checks out at the brake controller, move on to testing the 7-Way with a circuit tester. Have someone sit in the truck and apply the manual override on full while you test the 7-Way for the brake signal. If it comes through then you know the problem is on the trailer.
If nothing comes through then there could be a break in the wire between the controller and 7-Way. You will need to inspect the wiring to check for breaks. You will also want to make sure the ground is attached to a clean metal surface.
If everything checks out on the truck then that would mean the problem is on the trailer side. Start by checking the vehicle and trailer connectors for dirt and corrosion. Then you can check the main ground on the trailer connector. Then, move on to the brakes themselves.
On each brake assembly there is a magnet. Each magnet has 2 wires, one for ground and one for power. Make sure the ground wires are attached to clean metal surfaces and check for nicks in the power wires.
You can also visually inspect the magnets. If you can see the windings coming through then the magnets will need to be replaced. To further test the magnets I have included a link to an FAQ article that will help you.
