Voyager Brake Controller Green Light Stays on and Brake Magnets Hum

Question:

I drive a winnebago adventurer and tow vehicle with tow dolly once i hook it up green light comes on and brakes hum. what can i do other than unplug unit when i stop over night. tekonsha voyager was on motor home when i purched it new. thanks for your help.

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Expert Reply:

Brake controllers do send back a minimum amount of voltage to check for a connected trailer but it should not be enough to activate the brakes.

The magnets humming makes me think there is a bit of a short. To determine where it is coming from the first step is to disconnect the trailer.

In the truck cab you will need to sever the blue wire several inches from the back of the controller. Then use a circuit tester such as # 40376 to test the end of the blue wire coming out of the controller. It should only have power when you apply the manual override. If it shows power at idle then there is something wrong with the controller and it will need to be replaced.

If it tests fine then reconnect the blue wire. Then move on to the truck side trailer connector. Many times, dirt or corrosion can cause a short in a trailer connector. Make sure the truck and the trailer side connectors are clean and free of corrosion inside and out.

You can test the brake output pin and it should only show power with the manual override. If it shows power any other time then there is a short somewhere between the connector and the brake controller you will need to track down.

If the truck side checks out fine then it could be the wiring to the brake magnets or the magnets themselves. Inspect the power wires to the magnets and look for pinched, frayed, or damaged wires and fix as needed. Make sure the ground wires are attached to clean and corrosion free bare metal surfaces.

You can visually inspect the magnets and if you can see the copper windings coming through the magnets will need to be replaced. To further test the magnets you can follow the help article I have linked. I have also included some help articles on testing and troubleshooting brake controllers for you.

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Michael H

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