Prodigy intermittant overload

[karonc]

I have a Prodigy controller installed in my Silverado, and tow a HitchHiker FW. The controller has worked for 2 years, but now I am getting an intermittant OL indicator on the controller. When applying the brakes, the controller will start to work, then OL flashes, and then controller works again. Sometimes OL is on when braking, and brakes don't work. The instruction manual doesn't give any suggestions as as to what to look for. I have swapped the controller with another Prodigy, but get the same results. Any help will be appreciated. Ron

[karonc]

I have a Prodigy controller installed in my Silverado, and tow a HitchHiker FW. The controller has worked for 2 years, but now I am getting an intermittant OL indicator on the controller. When applying the brakes, the controller will start to work, then OL flashes, and then controller works again. Sometimes OL is on when braking, and brakes don't work. The instruction manual doesn't give any suggestions as as to what to look for. I have swapped the controller with another Prodigy, but get the same results. Any help will be appreciated. Ron

[Fulltimer]

Perhaps you should pull the wheels and check the brakes. Magnets wear pretty fast.

[Ray,IN]

Inspect the brake wire that runs through the axles. The RV manufacturer drills a small hole in each end of an axle tube, then runs the brake wire through the tube. Since the inside edge of the drilled hole cannot be de-burred easily, they don't. This sharp edge cuts through the wire insulation, creating an intermittent direct short to ground as the trailer moves, and the OL condition on your controller.
This may not be your particular case, but it is the majority of such complaints.
My solution is to run a new wire, wire-tied to the outside of the axle.

[porscheracer]

You have an intermittent short to ground. Whether it's in the truck harness, trailer harness, or a bad solenoid will take some troubleshooting to determine. In a case like this, a detailed inspection may well yield more information than electrical testing.

Sorry I don't have a magic fix.

[K-Star]

I had the very same issue and it was a brake wire shorting to ground at the trailer wheel. Like Ray said, they go thru a small hole and during travel vibration causes the wire insulation to wear thru.

[ParTheCourse]

Under Q&A on their web sight:

http://www.tekonsha.com/faqprodigy.html



it says:

Q.) The Display shows "OL".A.) The Prodigy® detects an overload caused by a short to ground on the brake wire (Blue wire). The Prodigy has to have a complete circuit from the control to the brake magnets to the ground and has to have the proper resistance. Possible Causes:


· Short to ground on the brake circuit wire.
· Trailer has electric over hydraulic brakes.
· Faulty control.


Hope this gives a clue and some help.

[MrFixit454]

Had the same problem... checked everything per Tekosha instructions. All magnets were at the correct resistence. All wires looked good. This unit was about a year and a half old. It worked fine until about 50 miles of driving. Then I would get the intermittent OL. It would then only work under 30 mph after the 50 mile or so run. Took it back to camping world and they gave me a new one.

What I don't like about the features this unit offers is that if it detects something wrong.. it quits working. This might be good in some situations but in the case of a bad magnet, I would rather stop w/ 3 brake shoes than none!