Electric brakes got me baffled

I usually keep my brakes working without too much trouble but I've got one trailer that is getting the best of me. Maybe one of you all can see what I'm missing. Here's what I've done so far:

Hitched truck to a buddy's trailer, I can lock them up both on the pedal and on the manual over-ride, so I'm assuming its not the truck.

Hitched to the problem trailer, I have all lights working so I'm assuming I have a good ground.

I can hear clicking from the brakes but have no braking effort.

I have 11 volts at the connector on the truck, and at the first junction box on the trailer on the brake circuit. It varies down to 5 volts as you turn down the controller as expected. This is with the engine off so probably another volt or two when running.

I removed both wheels on one side and inspected the innards. Magnets show some wear but not worn down to the cores (the trailer is older but only has I'd guess 10,000 miles on it). Pads are good, no uneven wear. I did set them up a little with the adjuster, but still no work.

I followed the wiring along the frame and between the axles, no indication of corrosion or bad connections.

So, I plan to open up the other side tonight and see if one of the magnets is shorting and taking all the current. I also thought about running a hot wire directly to the junction box from the truck and see if I can bypass the controller and trailer wiring to that point. I've had magnets fail before but not all four at the same time, so I can't help but think it is a wiring issue. Any ideas?

You can't "see" a bad connection especially when they are all covered by insulation, shrink wrap, and/or various forms of weatherproofing goop.

Have someone push the pedal for you while you look, listen and spin the tires. Maybe you can feel a difference in one wheel.

3 volts are required to activate the brakes so if you have 5 with a meter then I would assume your ground wires at the drums are bad.

Clean up the spot where the ground attachs at the hub and see what happens.

Gary

You can never have too good of a ground--Just not possible !

Don't "assume"-- check it and shine it up.

Electric brakes and oil/grease on the magnets are also a no-no.

My controller was only getting 5v at the brake called trailer man and he said i needed a new controller as that wasnt enough v at the brake got a new one and presto great brakes. Jack up alxe and put 12v at the brake and spin the wheel see how quick the wheel stops.

Brake mag ground is poor. BTDT and I ran a wire from the magnet straight to the plug and that to my battery no more problems that way

I had the same trouble with my brakes,replaced the little battery on the trailer and the brakes are back. Let us know what you find wrong.DON

I would bet that you do not have a good ground at the axle. You should be able to hear the magnets hum. I have had to run a ground wire right back up to the plug to keep them working regularly.

When you have the wheel drums off, put a screwdriver in front of the magnet and apply brakes. Real hi-tech. No magnet pull, No brakes.

Don't really have to use controller. Pull safety wire and the on board battery should produce 12v and a real strong magnetic pull. Should do this test to make sure battery/safety system works.

I had something flip up and cut a wire going to the brakes on my back axle.

I take two needles and poke through the wire insulation to measure the voltage at the electro-magnet. Someday, I'll solder a needle to the voltmeter's probes to make it easier to do.

George

Unhitch the trailer and just hook up the electrical connection. This way you can make sure the truck-trailer ground is working. Depending on the hitch for a ground connection does not work very well.

Make sure you seal off the needle holes in the insulation. Corrosion will get you if you don't.
We had a phone maintenance person who had a clip with a razor blade to check wiring in the roadside posts. Couldn't figure out why we were always loosing our service, until I finally put him on to it. DUH!