12-1/4” x 3-1/2” Electric Wheel Brake

Installation Instructions
A-216
819-0244

An Altra Industrial Motion Company

Contents Failure to follow these
instructions may result in product damage,
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 equipment damage, and serious or fatal
Technical Specifications. . . . . . . . . . . . . . . . . . . . 3 injury to personnel.
Installation Instructions
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Preparing the Brake Mounting Surface . . . . . . 3
Installing on Axle Flanges. . . . . . . . . . . . . . . . . 3
Installing the Brake . . . . . . . . . . . . . . . . . . . . . 4
Preparing the Brake Drum. . . . . . . . . . . . . . . . 4
Adjusting the Brake. . . . . . . . . . . . . . . . . . . . . 5
Installing the Trailer Brake Wiring. . . . . . . . . . . 5
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . 6
Towing Products Required with your
12-1/4” x 3-1/2” Brakes
Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Load Control. . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front Axle Resistor . . . . . . . . . . . . . . . . . . . . . 8
Warranty. . . . . . . . . . . . . . . . . . . . . . . . Back Page

Dimensions when used with .224/.205 Armature, Warner Electric Part No. 110-0124

.290/.265 Dia. (6) holes equally spaced on 1/2–20 UNF-2A, (6) req'd.
11.000 dia. within .007 R. of true position Equally spaced on 5.500 dia. within
(C'sunk for 1/4 dia. 80° flat head machine .005 R. of true position to
screws with nuts and lockwashers, or 80° flat head rivets) 4.510/4.503 pilot diameter

.170 min. .540

dia. min.

(2) 1/4 dia. terminal studs

A
2.125
max. 4.510 14 1/8 dia.
4.515 4.503
4.490 pilot dia.
A dia.
12.260
11.750 12.250
Section A–A 11.715 finished
dia. drum dia.

4 Torque to
71-79 ft. lb.

1.100 min.

The magnet arm will

clear a maximum axle
of 3 1/2" diameter
or a 3" square 12.225 .125 ref.
positioned as shown factory adjustment diameter over brake linings 1 2
12.195 3 .224
.205 3.567
3.507
Face View of Brake Assembly
(Drum and armature removed) 3.881 min.
4.068 max.
4.381 min.
4.752 max.

Right hand brake shown

Left hand brake opposite
Drawing No. I-26117
2 Warner Electric • 800-825-9050 A-216 • 819-0244
Technical Specifications
3.060
3.030
.535
Brake Rating – 7,500 lbs. to 10,000 lbs. axle rated .525 1.530
1.515
.140
.120
DIA. (6) HOLES
per pair. Based on an average retarding torque which EQUALLY SPACED.
LOCATED WITHIN

will produce a minimum of 43.5% retardation, or 14 .005 R. OF

TRUE POSITION.
60°

ft./sec.2 deceleration from 20 mph initial velocity with

13.3 in. to 17.2 in. rolling radius tires, with 10.8 volts
3.060 4.500
at the magnets. 3.030 4.498
DIA.

1.530 6.625
6.595
Mounting – 6 holes on 5.5” B.C. 1.515
DIA .

Electrical – 12 Volt D.C. system only

5.500

Lining Area – 90 sq. in. DIA. B.C. .140 R. Max.

Drum Swept Area – 135 sq. in.

Axle Flange
Lining Thickness – 5/16” nominal
Assembly Weight – 25 lbs. per brake Flanges available from a factory source.
7 lbs. per armature

Note: Use with armature type drum only.

A. Preparing the Brake Mounting Surface

12-1/4” x 3-1/2” Utility Brake
Before installing the brake, check the concentricity
Installation Instructions
and squareness of the brake drum to the hub and
spindle. To do this, mount the drum on the spindle
The performance of your Warner Electric 12-1/4” x
according to the manufacturer’s specifications.
3-1/2” brake depends greatly on accurate installation.
Since proper installation helps to assure long life
The following tolerances must be held:
and dependable performance, please follow these
installation instructions carefully. Pay particular
Drum friction surface concentric to spindle centerline
attention to drawing I-26117 on page 2 of the
within .015-inch T.I.R. (Total Indicator Reading).
manual.
Armature surface square to spindle within .020-inch
T.I.R.
General Instructions
B. Installing on Axle Flanges
The Warner Electric 12-1/4” x 3-1/2” utility brake
1. The axle flange on which the brake mounts must
is designed for use with one-piece steel armature
have a 4.500/4.498-inch pilot diameter.
number 110-0124, mounted inside the brake drums.
2. This axle flange must be welded concentric to
For other possible combinations, please consult
the spindle within .015-inch T.I.R. (measured at
your Warner Electric sales representative or Warner
the pilot diameter). The axle must be square to
Electric at 815-389-3771.
the spindle within .010-inch T.I.R. (measured at
the brake mounting surface). Refer to drawing
I-26117.

Warner Electric • 800-825-9050 A-216 • 819-0244 3

C. Installing the Brake 3. Tighten each of the six nuts with lockwashers to
Note: Brakes are designed as either right hand or 71-79 ft.-lbs. torque. Tighten them alternately
left hand assemblies by the RH or LH marked on the and evenly before applying full torque (see Figure
outside of each backing plate. (See Figure 1). The 3). Note that the pivot pin also serves as a
arrow on Figure 1 indicates the direction of forward mounting stud. Retorque the nuts after 50 miles
travel. of driving and periodically thereafter.

4. After the brake has been mounted to the flange,

operate the lever arm to assure that it moves
freely.

Figure 1 - Brake Designation

1. Mount the brake to the axle flange with the
anchor pin at the top, the magnet at the bottom,
and the curve of the actuating lever pointing Figure 3 - Tightening Nuts
toward the front of the trailer (see Figure 2).
D. Preparing the Brake Drum
Armature mounting holes are drilled in the brake drum
as indicated on the dimensional drawing
I-26117, page 2.
Warner Electric Armature P/N 110-0124
(.224/.205 thick)
a. Fasten this one-piece steel armature inside
the drum with (6) 1/4-inch diameter flat head
machine screws with nuts and lockwashers
Front (Step b) or (6) 80° flat head rivets (Step c).
of Trailer
b. Fasten each machine screw with two nuts
tightened against one another to prevent
loosening. Peening the ends of the screws
is recommended as an additional safeguard
Figure 2 - Mounting Position
against loosening.
2. Check to be sure that the brake backing plate
mates properly to the axle flange pilot. The brake
must be square with the spindle when bolted
into place.

4 Warner Electric • 800-825-9050 A-216 • 819-0244

 c. Install the rivets according to the drum c. Back off the adjuster (downward motion
manufacturer’s recommendations. of the adjusting tool) until the wheel turns
freely, usually 4 to 5 notches on the
d. Install the brake drum according to the adjusting nut.
manufacturer’s recommendations.
d. Replace the plug to keep out dirt and
E. Adjusting the Brake
moisture.
1. New brakes come pre-adjusted from the factory
and normally should not require additional e. Brake readjustment is recommended after the
adjustment when mated with new drums. The first 500 miles of operation (when shoes and
drum should, however, be checked for freedom drums have been seated).
of rotation after mounting. If dragging occurs, the
brake must be readjusted. F. Installing the Trailer Brake Wiring
1. Wire the brakes in parallel according to the wiring
2. Brakes should always be readjusted when they
diagram (Figure 5).
are installed with remachined drums. Note:
Brakes should never be installed in used
2. Use good quality, insulated, crimp-type
drums without remachining the drum
connectors that fit 1/4-inch diameter terminals to
braking surface.
attach the wires to the brake.
3. Follow these instructions to adjust the brake:
3. Remove the top nut, and check that the bottom
nut remains tight.
a. Remove the adjuster plug located at the
bottom of the brake and insert an adjusting
4. Install one connector over each 1/4-inch stud
tool (see Figure 4).
terminal with a star washer under the connector.
Lock into place with the top nut.

Figure 4 - Brake Adjustment

b. With the wheel off the ground, expand

the shoes until the brake drags
significantly. The shoes are expanded
by the upward motion of the adjusting tool
which turns the adjusting nut.

Warner Electric • 800-825-9050 A-216 • 819-0244 5

 BRAKE

FRONT REAR

TRAILER PLUG

GROUND WIRE

BREAKAWAY
1110-41
SWITCH
FRONT AXLE
RESISTOR
NEGATIVE TERMINAL BATTERY

TRAILER

Figure 5 - Brake Wiring

Replacement Parts

All wearable parts are replaceable with factory

original components packed in convenient kits
complete with instruction sheets. These kits are
available through Warner Electric’s Distributor
Network.

Shoes & Linings/Shoe Hold Down Spring Kit

Kit No. 1301-100-005

Magnet Kit
Kit No. 1301-100-014
Shoe Return Spring Kit
Kit No. 1301-100-008

6 Warner Electric • 800-825-9050 A-216 • 819-0244

 Armature Kit Terminal Accessory Kit
Kit No. 1301-100-013 Kit No. 1301-100-011

Adjuster/Adjuster Spring Kit

Kit No. 1301-100-006
Lever Arm Kit, L.H. Lever Arm Kit, R.H.
Kit No. 1301-100-016 Kit No. 1301-100-015

Mounting Accessory Kit

Kit No. 1301-100-003

Warner Electric • 800-825-9050 A-216 • 819-0244 7

Towing Products Required with Your Load Control
12-1/4” x 3-1/2” Brakes
The installation of 12-1/4” x 3-1/2” brakes on any
The following section, “Towing Products Required trailer which will operate with loads less than rated
with your 12-1/4” x 3-1/2” Brakes,” describes capacity or with varying loads requires a load control,
associated controls and components necessary to Warner Electric part number 1300-78, to be installed
complete your brake system installation. Please read in the towing vehicle. The Warner Electric Load
it carefully. Control compensates for trailer load variations by
limiting the maximum torque output of the brakes by
Controller adding dropping resistance in the electrical control
line. When towing a trailer loaded to brake rated
Warner Electric has one controller available capacity, the Load Control must be set at maximum
specifically for use with the 12-1/4” x 3-1/2” brake. braking. When pulling an empty or partially loaded
The Utility Controller, Warner Electric part number trailer, the Load Control must be set between
1300-76, is rated at 30 amps and 4, 6 or 8 brakes. maximum and minimum braking at a position just
This controller is designed to properly synchronize before the point at which trailer tire skidding occurs
the towing vehicle and trailer brakes. Using other when actuating the hand control fully on. Failure to
controllers may result in excessive trailer brake torque install and use the Warner Electric Load Control will
causing jerky braking and poor towing vehicle-to- result in excessive brake torque when stopping a
vehicle braking synchronization. trailer loaded to less than brake capacity.

Warner Electric’s Utility Controller has an adjustment

knob to control trailer brake torque. Labeled “More” Front Axle Resistor
(braking power) and “Less” (braking power), this
adjustment does not affect maximum braking The Warner Electric Front Axle Resistor, part number
capacity of the trailer brakes. Because of the wide 1100-41, is designed to balance braking forces
variety of towing vehicles encountered, balancing between front and rear axle on two-axle trailers. Utility
towing vehicle brakes and trailer brakes is necessary trailers with tandem axle rocker arm suspension
for smooth, synchronized stops. To achieve this, the present a typical application. This suspension tends
controller adjustment should be set to provide a slight to transfer weight from the front axle to the rear
lead in trailer braking over towing vehicle braking. axle during braking, allowing the front wheels to
Turning the adjustment knob in the “More” direction prematurely lock and skid. By automatically reducing
will increase the trailer brake rate of application, while the current flow, the Warner Electric Front Axle
turning in the “Less” direction will decrease the trailer Resistor reduces front axle braking forces to improve
brake rate of application. When proper adjustment brake balance, reduce tire wear, and minimize the
has been achieved, there should be no sensation of wheel lock-up.
the trailer pushing or pulling the towing vehicle during
a stop. When this setting has been reached, no
further adjustment should be required. For operating
with varying load weights, read the following section
on “Load Control.”

8 Warner Electric • 800-825-9050 A-216 • 819-0244

 NOTES

Warner Electric • 800-825-9050 A-216 • 819-0244 9

 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.

An Altra Industrial Motion Company

www.warnerelectric.com
4578 East Park 30 Drive
Columbia City, IN 46725
260-244-6183
www.altramotion.com
Fax: 260-244-392

A-216 • 819-0244 5/14 Printed in USA