Troubleshooting Timed Brake Controller Wiring And Bench Test Procedure

Question:

I have power to the red wire at the back of the controller. On the blue wire it barely makes a tiny light on the tester. Is the controller bad or could it be bad connections somewhere?

asked by: Ronald M

Expert Reply:

You could have a bad connection on your Draw-Tite Activator Trailer Brake Controller 5100. Since this is a timed brake controller the power going to the brakes will vary based on how long the brake pedal is pushed.

The red wire is the signal that comes from the brake pedal switch to tell the controller when to brake. You will need to check that all the other wires have a good connection and not damaged.

The black wire is your main power wire. Depending on your vehicle this will either have a fuse, relay or both. You will need to check your owners manual for their location if it is a factory connection. If the brake controller is hard wired in you will need to follow the wiring to the battery and inspect the connection.

The white wire is a ground wire. Be sure to verify that it has a clean ground connection.

The blue wire you will want to check the voltage with a Multimeter # PT89ZR at the back of the controller to the 7-way connector. Voltage should be within 1 volt of battery power.

You can also bench test this controller using a 1156 Bulb # DI49VR. The bulb will get wired to the blue wire with the ground wire from the bulb and the white wire connecting to the negative terminal on a 12v battery. You can leave the red wire disconnected for the first part of the test. Attach the black wire to the positive terminal on the battery. When you activate the manual brake lever the bulb should light up. Be sure controller is set to maximum output. If that checks out you can touch the red wire to the positive terminal as well to mimic that the brake pedal is pushed. The bulb should light when you touch the red wire to the positive terminal.

I have linked a copy of the instructions below for you to reference as well.