3
Warner Electric • 800-825-9050 819-0128
Note: Use only 10 or 12 gauge wire meeting
SAE Specification J558a for connecting the
Load Control.
Strip the insulation back about 1/4" from each cut
end. Insert one stripped end into each of the two
insulated ring terminals provided. After inserting
the full length of bared wire, crimp the terminal
using AMP hand tool 59239-4 (G9150-7 for thin-
wall insulation) or equivalent. Assemble the wired
terminals to the Load Control, but do not tighten.
One lead is to be attached to the center terminal,
the other to the left hand (heavy resistance wire
side of the resistor) terminal when facing the rear
of the resistor. (See Figure 3)
Figure 3
Under Instrument Panel Installation
Mount the case under the instrument panel,
inserting the tapping screws (with heads inside
the control case) provided through the newly-
drilled holes and tightening securely to the speed-
nuts included with your Load Control.
Remove the jam nut from the Load Control shaft
and insert the shaft and the washer projection into
the holes provided in the front portion of the case.
Place the Load Control into the case so the wash-
er projection protrudes through the case front.
Position the dial face on the case and tighten the
jam nut securely with the washer locating tab pro-
jecting through its locator hole. Assemble the
hand knob to the control shaft, positioning it so
the knob screw opposite the pointer sets against
the control shaft flat. Tighten the setscrews
securely. Tighten both electrical terminal connec-
tions, carefully positioning the lead wires so the
ring terminals will not contact the sides of the
case.
Behind Instrument Panel Installation
Remove the jam nut from the Load Control shaft
and insert the shaft and the washer projection
into the holes provided in the front portion of
the case.
Insert the Load Control into its case so the
washer locating tab protrudes through the case
front. Insert the control shaft and locating tab
into the holes provided in the instrument panel.
Position the dial face on the control shaft and
tighten the jam nut securely with the washer
locating tab projecting through the case instru-
ment panel, and dial face. Assemble the hand
knob to the control shaft, positioning it so the
knob setscrew opposite the pointer sets against
the control shaft flat. Tighten the setscrew
securely. Tighten both electrical terminal con-
nections, carefully positioning the lead wires so
the ring terminals will not contact the sides of
the case.
Since the Load Control can
become very warm during normal operation,
the case must be used with the control
whether it is mounted under or behind the
instrument panel. When installing the Load
Control, take care to assure that all electrical
wires and other underdash components are
securely fastened to prevent accidental con-
tact with the resistor winding.
Adjustment
Your Warner Electric Load Control will help com-
pensate for trailer load variations by limiting the
maximum torque output of the brakes by adding
dropping resistance in the electrical control line.
When towing a trailer loaded to brake rated
capacity, the Load Control must be set at maxi-
mum braking. When pulling an empty or partially
loaded trailer, the Load Control must be set
between maximum and minimum braking at a
position just before the point at which trailer tire
skidding occurs when actuating the hand con-
trol fully on. Failure to use the Warner Electric
Load Control properly can result in excessive
brake torque when stopping a trailer loaded to
less than brake capacity.
