Warner 1300-78 User manual

Installation Instructions
P-1385
819-0128
12 Volt Load Control for Electric
Brake Systems No. 1300-78
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

2Warner Electric • 800-825-9050 819-0128
The Warner Electric Load Control provides the
capability to properly proportion the braking
power of the trailer brakes to the trailer weight.
The Load Control is a variable resistor which
allows the operator to reduce current flow to the
trailer brakes by turning the control knob.
Depending on road conditions and trailer load,
the knob can be set at any position between
“MIN BRAKE” and “MAX BRAKE”. The Load
Control provides a broad range of adjustment to
suit a wide variety of operating conditions.
Failure to follow these instruc-
tions may result in product damage, equip-
ment damage, and serious or fatal injury to
personnel.
Specifications
Resistance Rating: 0-5 ohms
Voltage: 12 volts DC
(use only with 12 volt system)
Brake Coil: Designed for 2-4 brakes wired in
parallel, each with 3.0-3.5 ohms coil resistance.
Installation
Mounting the Control
The Load Control should be mounted under or
behind the towing vehicle’s instrument panel to
the left or right of the steering column, depend-
ing on available space and driver preference.
To mount the Load Control, sit in a normal driv-
ing position and place the Control case so its
knob is within easy reach. (See Figure 1)
Figure 1
For under-dash mounting proceed as follows:
1. While holding the Load Control case in posi-
tion, mark the underside of the instrument
panel through the two mounting holes in the
case.
2. Drill two 13/64" diameter holes where
marked, being careful not to damage any-
thing under the instrument panel.
For behind instrument panel mounting proceed
as follows:
1. Position the face of the Load Control shaft
hole and the washer projection hole.
2. Drill a 13/32" diameter hole for the Load
Control shaft and a 3/16" diameter hole for
the washer projection, where marked. Be
careful not to damage anything under the
instrument panel.
Electrical Connection
The Load Control is to be wired in series with
the electric brake controller and the trailer
brakes. Refer to the “Typical Wiring Diagram” to
connect the Load Control into the brake system.
(See Figure 2)
Figure 2
Mount on either side
12v
Battery
Stoplight
switch
Utility controller
mounted on dash
Fuse Red
Blue
Socket
to Stoplight
Starter
Black
10 Gauge Wire
recommended
Load control
1300-78
(Optional)
Typical Wiring Diagram
Warner Load Control 1300-78
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

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.
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]

Warranty
Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any
product manufactured and sold by it which proves to be defective in material or workmanship
within a period of one (1) year from the date of original purchase for consumer, commercial or
industrial use.
This warranty extends only to the original purchaser and is not transferable or assignable without
Warner Electric LLC’s prior consent.
Warranty service can be obtained in the U.S.A. by returning any defective product, transportation
charges prepaid, to the appropriate Warner Electric LLC factory. Additional warranty information
may be obtained by writing the Customer Satisfaction Department, Warner Electric LLC, 449
Gardner Street, South Beloit, Illinois 61080, or by calling 815-389-3771.
A purchase receipt or other proof of original purchase will be required before warranty service is
rendered. If found defective under the terms of this warranty, repair or replacement will be made,
without charge, together with a refund for transportation costs. If found not to be defective, you
will be notified and, with your consent, the item will be repaired or replaced and returned to you
at your expense.
This warranty covers normal use and does not cover damage or defect which results from
alteration, accident, neglect, or improper installation, operation, or maintenance.
Some states do not allow limitation on how long an implied warranty lasts, so the above limitation
may not apply to you.
Warner Electric LLC’s obligation under this warranty is limited to the repair or replacement of the
defective product and in no event shall Warner Electric LLC be liable for consequential, indirect,
or incidental damages of any kind incurred by reason of the manufacture, sale or use of any
defective product. Warner Electric LLC neither assumes nor authorizes any other person to give
any other warranty or to assume any other obligation or liability on its behalf.
WITH RESPECT TO CONSUMER USE OF THE PRODUCT, ANY IMPLIED WARRANTIES WHICH
THE CONSUMER MAY HAVE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF
ORIGINAL CONSUMER PURCHASE. WITH RESPECT TO COMMERCIAL AND INDUSTRIAL
USES OF THE PRODUCT, THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL
OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR
OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty gives you specific legal
rights and you may also have other rights which vary from state to state.
Changes in Dimensions and Specifications
All dimensions and specifications shown in Warner Electric catalogs are subject to change without
notice. Weights do not include weight of boxing for shipment. Certified prints will be furnished
without charge on request to Warner Electric.
Warner Electric LLC
449 Gardner Street •South Beloit, IL 61080
815-389-3771 •Fax: [phone]
www.warnerelectric.com
P-1385 819-0128 6/05 Printed in USA
®
DIST. AUTORIZADO
MEX (55) 53 63 23 31
QRO (442) 1 95 72 60
MTY (81) 83 54 10 18
[email protected]