Troubleshooting Hopkins Agility Brake Controller That Clicks But Does Not Apply Brakes  

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Expert Reply:

Hopkins brake controllers like the Agility part # HM47295 are a little more prone to developing internal shorts than other controller so it's possible the controller either has an internal problem that can be fixed by a hard reset (unplug then plug back in) or is damaged to the point it needs to be replaced. I might be jaded from past experiences but I am pretty confident it will need to be replaced, but here's how to test everything to determine exactly where the problem is if the reset does not fix it.

Testing the brake controller is fairly easy. Sever the blue brake output wire near the brake controller leaving enough room to reconnect it and then apply the manual slide. Using a circuit tester like the Tester, part # PTW2993, you should get output to the controller side of the wire you severed. If the manual slide activates the trailer brake output wire properly, try the brake pedal. If the brake pedal activates the brake output properly also then the problem is farther back either in the vehicle wiring or on the trailer.

If either the brake pedal or the manual slide are not functioning properly you will need to test the wires going into the brake controller. Make sure you have power entering the brake controller on the black wire. On the red wire you will only want power when the brake pedal is pressed.

If there is power on the red wire before the brake pedal is pressed you have connected the red wire from the brake controller to the wrong circuit. You would then need to find the brake switch wire that has power ONLY when the brake pedal is activated.

If these connections check out and the brake controller is properly grounded then there is possibly a problem inside the brake controller.

I am including a link to a video that will show you how to test the wiring on a brake controller.

If the controller is bad and needs to be replaced the part # TK63VR is a similarly priced proportional brake controller that has proven to be much more reliable than your Agility so that would be what I would recommend as a replacement.

expert reply by: Jameson C

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