Voyager Brake Controller Does Not Show Voltage with Manual Override Applied  

Question:

Expert Reply:

The way a brake controller works is sort of like you described. In many proportion controllers, you actually have to be moving to get voltage when applying the brake but will see voltage when applying the manual override. The controller actually senses how much the vehicle is decelerating using an internal sensor. It does not monitor how hard you press the pedal but it does sense when you are pressing the brake. Of course usually how hard you press the brake does effect the rate of deceleration.

If the output level is set too low, applying the manual override will only go up to the level it is set on but no higher. Try adjusting the power higher and test the manual override again. But, instead of testing it at the back of the truck, test it at the controller by severing the blue wire from the back of the controller.

Use a circuit tester to test the end of the blue wire coming out of the controller. You should get power on the blue wire when you apply the manual override, but not necessarily the brake. If there is no power coming through with the manual override, try apply it on full and then let it snap back into place several times to clean the contacts inside and then test again.

If you still do not get power with the manual override then there is something not right inside the controller and it will need to be replaced.

Another possibility is that the controller is mounted outside of its range. I have linked the instructions for you to view. Make sure that the controller is mounted as described in the instructions and that the level knob is in the correct position. The controller can be mounted as high as 70 degrees nose up or 20 degrees nose down. It cannot be tilted or turned side to side. It must be level with the direction of travel.

expert reply by: Michael H

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