Electric brake troubleshooting

Submitted: Thursday, Feb 25, 2010 at 15:29
ThreadID: 76326 Views:9689 Replies:6 FollowUps:7
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I have a 1982 Viscount Grand Tourer pop-top. I have upgraded the override brakes to electrics. Mechanically everything was easy.

I got the local auto electrician to install a Tekonsha Prodigy brake controller to the tow vehicle - a 2004 Kluger. Meanwhile I connected the designated blue wire in the Viscount harness to the brakes.

Took the unit out on the road in a nearby subdivision and did a test run and everything worked correctly.

Final touch was to clamp the override section of the hitch to disable the van from activating the brakes the old way.

First trip was down the mountains (from Orange NSW) to the Lane Cove van park at North Ryde. On the way we noticed that the Prodigy was flashing red and giving the warning "Overload". The brakes became a bit grabby as though pulsing on and off - fortunately we were travelling slowly at the time.

Finally back in Orange I went back to the auto electrician whose diagnosis was the controller - he "doesn't like" Tekonshas. He reckoned I needed something I could adjust the Gain, so I replaced the Prodigy with a Voyager unit.

Similar problem with the brakes grabbing and releasing - I guess you'd call that overload.

I have dialed down the gain so much that I decided I should take the clamp off so that the override braking is reactivated, while I only use the electrics by sliding the lever across in manual mode.

What am I missing here? Is there something wrong with how the electrician has wired the controller? Is it the wiring? Or is it the settings?

Any help would be appreciated.
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