Brake Controller Overload
Prodigy Controller (10 years old) works intermittently then fails and reads OL or SH. Cleaned 7-way plug and inspected wires not including inside drum. Took the TT for a spin and brakes still work s...
Forum Discussion
I would just replace the wires. I've just gone through the same thing this year with my P3. I would get intermittent brakes and the controller would either show the error for a short or an overload. Everything tested and worked fine while the trailer was stationary, but I would get the same problems as soon as I moved. Tested everything from the P3 back to the magnets. I decided to rip all of the wiring out, upgrade it to #10 AWG, run them outside of the axle, and upgraded the connections. My trailer is still under warranty, but I chose not to use it. I didn't want to bring it in only to have them return it back to that inferior system that will only fail again one day.
When it was all said and done, I found a few areas that could've been the source of them problem. All of my grounds in the 7 pin box, that were all joined by a wing nut, were badly rusted. There was a broken grommet where the wires went into one of the axles which rubbed away the insulation on a wire. The wires inside of the axle had rubbed so much, I could no longer tell the color of the wires. Some spots were getting pretty thin.
It was much easier to start over new than to fix / test each problem. Ever since the upgrade, no more problems. I have a theory why everything tests out fine. When you're testing, the wires aren't bouncing around and rubbing like they do while you're going down the road. When the trailer starts moving, so does the wires, and you get the short.
When it was all said and done, I found a few areas that could've been the source of them problem. All of my grounds in the 7 pin box, that were all joined by a wing nut, were badly rusted. There was a broken grommet where the wires went into one of the axles which rubbed away the insulation on a wire. The wires inside of the axle had rubbed so much, I could no longer tell the color of the wires. Some spots were getting pretty thin.
It was much easier to start over new than to fix / test each problem. Ever since the upgrade, no more problems. I have a theory why everything tests out fine. When you're testing, the wires aren't bouncing around and rubbing like they do while you're going down the road. When the trailer starts moving, so does the wires, and you get the short.
