Trailer Brakes Stay Engaged When Not Using Brakes or Override on Hopkins Agility Brake Controller

Updated 09/21/2010 | Published 09/20/2010

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Question:

I HAVE THE HOPKINS AGILITY ELECTRIC BRAKE CONTROLLER and I HAVE THE PLUG ADAPTER TO THE TRUCK and I JUST GOT A NEW TRAILER BUT WITH I PLUG IT IN TO THE TRUCK and PULL IT YOU CAN FILL THE BRAKES ARE ENGAGED A LITTLE IF YOU UNPLUG THE TRAILER OR THE CONTROL THE TRAILER PULLS FINE

asked by: JAMES

Expert Reply:

It sounds like you will need to set up the Hopkins Agility brake controller, # HM47294, as if you have just installed it. From time to time, settings can get changed and the controller can get knocked out of position and you might not notice.

Double check to make sure the controller is within the +70 to -20 degree range, and that it is not tilted to the left or right. If it is, the internal inertia sensor inside may be incorrectly reading braking activity and send too much power to the trailer brakes. To set up the brake controller, follow the OPERATING / SETTING YOUR CONTROLLER and TESTING / ADJUSTING THE BRAKING RESPONSE sections of the instructions linked below.

The manual override contacts could also be dirty causing the problem. To clean them, fully engage the manual override and then let it snap back into position. Do this several times to clean the contacts and then check to see if that fixed the problem.

Dirt and corrosion on the trailer and vehicle side trailer connectors could also be causing the issue you are having. I recommend checking them and giving each a good cleaning to clean off any dirt or corrosion present.

You can also test the brake controller wiring with the trailer connected to see if it is sending power along the blue wire when not stepping on the brake or using the manual override. You will need a circuit tester like # PTW2993. Probe the blue wire without touching the brake or manual override. If there is any signal, then there is a short to the blue wire which would mean a problem with the internal circuitry of the brake controller, and it would need to be replaced.

You may also need to adjust the brakes themselves. They could be tight enough that even a slight amount of voltage to the magnets causes the brakes to lock. If you believe this could be an issue, back the assembly adjusters out until the wheels spin freely. Next, slowly tighten them until the shoes make light, and even contact with the hubs. You want the slightest amount of even resistance while you spin the wheel.

expert reply by: Michael H