Prodigy O.L. (overload condition)

[tknick]

I have a prodigy brake controller that worked well for close to 1000 towing miles.  While on an extended trip, the controller started exhibiting O.L. condition.  The O.L. condition only exists during a braking event and only when the braking force exceeds 2.4 or 2.5.  During a light to moderate braking event, the unit performs as expected.  After exceeding the 2.4 area, the unit will flash between the braking force applied and O.L.  While flashing, you can feel the brakes being applied and released depending on what is flashing on the unit.  While stopped, the unit performs correctly applying the correct force and reducing to the holding brake force.  Also, while stopped, you can apply full force 10.0 or greater using the manual lever.  I understand the O.L. indicates a short somewhere.  I would assume it is somewhere in the trailer brake assembly because the O.L. only exists while the trailer is rolling.  Any suggestions in troubleshooting would be greatly appreciated.  Thanks

[wynot]

I have a prodigy brake controller that worked well for close to 1000 towing miles. While on an extended trip, the controller started exhibiting O.L. condition. The O.L. condition only exists during a braking event and only when the braking force exceeds 2.4 or 2.5. During a light to moderate braking event, the unit performs as expected. After exceeding the 2.4 area, the unit will flash between the braking force applied and O.L. While flashing, you can feel the brakes being applied and released depending on what is flashing on the unit. While stopped, the unit performs correctly applying the correct force and reducing to the holding brake force. Also, while stopped, you can apply full force 10.0 or greater using the manual lever. I understand the O.L. indicates a short somewhere. I would assume it is somewhere in the trailer brake assembly because the O.L. only exists while the trailer is rolling. Any suggestions in troubleshooting would be greatly appreciated. Thanks

I understand, but have never experienced, that sometimes the brake wiring can get chafed and subsequently short out, which might explain your situation because of a slight twist that might occur when braking lightly.

[AustinBoston]

I would start by inspecting the magnets.  This would reveal if they are highly or unevenly worn, exposing the wires inside.  It would also give you a chance to carefully examine the leads to the magnets, which may be shorting only during a braking event due to the movement of the magnet armature.

Austin

[tknick]

I would start by inspecting the magnets.  This would reveal if they are highly or unevenly worn, exposing the wires inside.  It would also give you a chance to carefully examine the leads to the magnets, which may be shorting only during a braking event due to the movement of the magnet armature.

Austin

I just repacked the bearings before this trip.  I looked at the magnets when I had the wheels apart and didn't see anything unusual according to the dexter manual I was using.  Can you be a little more specific about what I should look for (other than exposed wires) when I take the wheels apart again ?

Thanks Austin....

[AustinBoston]

I just repacked the bearings before this trip.  I looked at the magnets when I had the wheels apart and didn't see anything unusual according to the dexter manual I was using.  Can you be a little more specific about what I should look for (other than exposed wires) when I take the wheels apart again ?

Thanks Austin....

I'm not going to be able to describe better than the Dexter manual what to look for on the magnets.  But if they looked OK before the trip, then the problem is almost certanly with a lead from one of the magnets.

Look for anywhere the wire goes through a narrow space (such as where it goes through the backer plate) or might come into contact with a moving part.  Move the armature in the direction it would normally move while braking (towards the back of the pop-up) and watch how the wires move.  Remove any tape and replace it with new electrical tape.

Good luck,

Austin

[tknick]

I'm not going to be able to describe better than the Dexter manual what to look for on the magnets.  But if they looked OK before the trip, then the problem is almost certanly with a lead from one of the magnets.

Look for anywhere the wire goes through a narrow space (such as where it goes through the backer plate) or might come into contact with a moving part.  Move the armature in the direction it would normally move while braking (towards the back of the pop-up) and watch how the wires move.  Remove any tape and replace it with new electrical tape.

Good luck,

Austin

Thanks Austin!!!