Why Is My Brake Controller Running Hot And Locking Up Overnight
Question:
If I adjust my controller up enough to have any effective braking then they drag and get pretty hot, if I leave turned up over night then the brakes are locked up the next morning, POD brand controller, Thanks for your help
asked by: Stormy F
Expert Reply:
It sounds like your brake pin has constant 12V power and it should not. You will need a circuit tester, such as the Cordless Circuit Tester, part # PTW2979, so you can check the voltage on the brake output pin on your 7-way connector. This pin should be at the 5 o' Clock position on your 7-way connector. My guess is when you test that connector you will find that it reads 12V, but it should not read anything if the brake controller is not activated. I have attached a diagram that shows where your brake output pin is located on your 7-way connector.
You could also have a short caused by corrosion, this can happen on both connectors. Cleaning off any corrosion might solve this problem.
You can also test to see if it is the brake controller itself is the issue. This will require you to cut the blue wire, several inches from the controller and use a circuit tester to test the end coming from the controller. It should only show power when the manual override is applied. If it shows power any other time, it will need to be replaced.
Your magnets could also be causing this issue. Check the system for any frayed wires that could be touching bare metal. The grounds need to be attached and show no signs of corrosion. You can also inspect and test your magnets. I have attached an article that explains this process below.
Your brakes seem to be engaged all of the time, that is causing your brakes to drag, and they are heating up as a result. You might need to recheck your brake assemblies to make sure they are properly adjusted. Pay particular attention to frayed wiring and corrosion. I have included a link explaining how to check your brake controller below.
(click to enlarge)
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