Warner Electric Wheel-Brakes User Manual
12
Wheel-Brakes
1
⁄4 x 51⁄2, 15 x 3, 161⁄2 x 5-6-7 (Std)
1
16 x 2
⁄2, 171⁄4 x 3-4-5
AA-110
819-0514
Installation & Operating Instructions
Contents
Section l. Description And Operation . . . . . . . . . . . . . 4
Description and Operation. . . . . . . . . . . . . . . . . . . . 4
How to Break in Trailer Brakes . . . . . . . . . . . . . . . . 5
How to Apply Brakes . . . . . . . . . . . . . . . . . . . . . . . . 5
Section ll. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Prepare for Installation . . . . . . . . . . . . . . . . . . . . . . . 6
Install and Check Drum . . . . . . . . . . . . . . . . . . . . . . 6
Install Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install Armature in Drum . . . . . . . . . . . . . . . . . . . . . 8
Check Armature Depression . . . . . . . . . . . . . . . . . . 9
Adjust Armature Depression . . . . . . . . . . . . . . . . . 11
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . 11
Section lll. Maintenance. . . . . . . . . . . . . . . . . . . . . . . 12
Check Current Available . . . . . . . . . . . . . . . . . . . . . . . 12
Table I. Magnet Current Rating . . . . . . . . . . . . . . . 13
Check Amperage at Each Brake . . . . . . . . . . . . . . 14
Check for Lining Wear . . . . . . . . . . . . . . . . . . . . . . 14
Table II. Lining Wear. . . . . . . . . . . . . . . . . . . . . . . . 14
Check for Loose Wheel Bearings . . . . . . . . . . . . . 15
Inspect Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drum and Lining Clearance . . . . . . . . . . . . . . . . . . 16
Relining Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table III. Drum Rebore and Brake
Reline Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Check Magnet and Armature. . . . . . . . . . . . . . . . . 17
Replacement of Magnets and Armatures . . . . . . . 18
Table IV. Magnet and Armature Wear . . . . . . . . . . 19
Testing Magnet. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Replacing Magnet Leads . . . . . . . . . . . . . . . . . . . . 21
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Page
Warner Electric • 800-825-9050 819-0514
2
Brake Band
Magnet
Cam Lever
Trunnion
Armature
Drum
Spider
Brake Band
Dust Cover
Magnet
Cam Lever
Armature
Spider
Trunnion
Dust Cover
Brake Shoe
2-1/4 x 5-1/2 Brakes
Armature
Magnet
Cam Lever
Amature Adapter
Drum
Trunnion
Armature
Brake Band
Magnet
15 x 3 Brakes
Backing Plate
Drum
Trunnion
Cam Lever
16-1/2 x 5-6-7 Brakes
Warner Electric • 800-825-9050 819-0514
16 x 2-1/2 and 17-1/4 x 3-4-5 Brakes
3
Failure to follow these instructions
may result in product damage, equipment damage,
and serious or fatal injury to personnel.
Section l
Description and Operation
The Warner Electric Brake is basically a mechanical
friction brake which uses a simple principle of
electricity for its actuation. The small amount of
electrical current required is obtained from the storage
battery and/or generator with which every towing
vehicle is equipped.
Unlike the ignition system of the engine, the Warner
Electric Brake does not require the use of high tension
current; therefore, no harmful shock is possible.
The main components of the Warner Electric Brake
are the backing plate or brake spider, magnet,
armature, brake band or brake shoes, cams and brake
drum; the nomenclature of the brake components
being dependent on method of fabrication, design,
and to some extent on brake size. With the
electro-mechanical actuating components (magnet
and armature) removed, (Figure 1-1), the brake consists
of a brake spider, which is mounted on the axle flange
and supports the brake shoes and cams. These
components are similar to, and functionally the same
as, those components found in all other mechanical
friction brakes.
The electro-mechanical actuating components
comprise a “friction clutch” and serve to generate the
force which multiplied by the cams, presses the brake
shoes into the brake drum. One plate of this “clutch” is
the armature, (Figure 1-2) which is bolted to the drum
and rotates with the wheel. The other plate of this
“clutch” is the magnet, (Figure 1-3) which is mounted
on the brake spider and is free to rotate a limited number of degrees in either direction. When the “clutch” is
engaged (upon application of an electric current to the
magnet) any movement of the trailer wheel (forward or
backward) causes the magnet to rotate and braking
results.
Figure 1-2
Armature Assembly
Brake Shoe
Cams
Figure 1-1
Electric Brake—Magnet Removed
Brake Spider
Dust Cover
Figure 1-3
Magnet Assembly
Warner Electric • 800-825-9050 819-0514
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Operation
How to Break in Trailer Brakes
When the magnet rotates, a trunnion, located on the
back of the magnet, moves the cam. The cam, bearing
on the brake shoe end, moves the brake shoe into
contact with the brake drum. After the toe end of the
brake shoe is forced against the brake drum, the shoe
(being free to float on its support and somewhat flexible in structure) will tend to follow the drum until the
complete brake shoe assembly is making contact with
the drum. The brake shoe is limited in its travel, however, since the heel end is forced against an anchor,
which is part of the brake spider assembly.
As the amount of current applied to the magnet is
increased, the attractive force between the magnet and
armature becomes greater. With an increase in attractive force between magnet and armature, more torque
is developed by the “clutch” and the pressure exerted
by the magnet trunnion upon the brake shoe (through
the cam) increases; and the shoe is pressed tighter into
the drum.
Until the vehicle is brought to a stop, slippage between
the magnet and armature occurs. However, if during a
stop sufficient pressure is built up, slippage between
the magnet and armature ceases and the entire unit
(magnet, armature, brake shoe, and brake drum) will
lock and slide the tire, providing the brake is of proper
capacity for the wheel load.
No brake adjustment is necessary. The magnet movement is sufficient to wear the brake lining down to the
rivet heads if the proper brake shoe to drum clearance
is maintained when new lining is present. When the lining has worn out, the cams come against a positive
stop (preventing further magnet rotation) preventing the
rivet heads from scoring the drum. Improper clearance
between brake shoe and drum initially will cause the
magnet to reach full travel before completely wearing
out the lining. In either case, as full magnet travel is
reached, a gradual loss of brake power will result.
Thus from the foregoing description, it is readily seen
that the Warner Electric Brake is a simple power-brake.
The amount of power developed being controlled by
the amount of current metered to the magnet by the
brake controls. Maximum power being achieved by an
amount of current approximately equal to that used by
a tail-lite.
When the armatures and magnets are new, to prevent
possible damage and to increase their efficiency, the
following steps should be followed during the initial
braking applications:
1. Attain a minimum vehicle speed of thirty miles
per hour and apply trailer brakes only until the
vehicle speed is retarded to approximately fifteen miles per hour, then release the brakes
allowing the vehicle to regain speed. DO NOT
LOCK THE WHEELS.
2. Next, drive for about one-half mile without
applying the trailer brakes. Repeat Step No. 1.
3. It will be necessary to follow Steps No. 1 and
2 until you have traveled approximately six
miles.
4. Allow the brakes to run free during the next
four miles. Then apply the brakes to check
their efficiency.
This procedure is also recommended whenever a
wheel has been pulled for maintenance of any kind or
when the trailer has set idle for any extended period of
time.
How to Apply Brakes
A brake is designed for a fixed capacity based upon
wheel load and tire size, and it is mounted in a minimum of space in order to clear springs and frames.
Considering this, it should not be required to handle
more than its own wheel load.
To obtain satisfactory trailer brake performance, the
towing vehicle’s brakes must handle their own load,
and therefore, must be applied simultaneously with the
trailer brakes. Consequently, the towing vehicle’s
brakes and the tractor trailer brake control system
must be kept in good repair to obtain maximum results
from the trailer brakes.
Overloading or using only the trailer brakes to stop the
complete tractor-trailer unit, will cause the heat absorption capacity of the brake to be exceeded. Hotter
brakes, longer stops, and shorter lining life will result.
Warner Electric • 800-825-9050 819-0514
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Section ll. Installation
Prepare Brake and Axle for Installation
The performance of an electric brake depends entirely
upon an accurate installation. Follow instructions, for
accuracy is definitely demanded and a brake properly
installed assures long life and dependable performance.
In preparing for installation, make certain that the hub
drum pilot (A, Figure 2-1) is at a perfect right angle with
the drum mounting surface (B), and that the drum pilot
(A) runs concentric with the axle spindle within .010”
total indicator reading. This may be checked on the
axle with a dial indicator or by removing the hub and
placing it in a lathe, using its own bearings on the
arbor for centering. If drum pilot bore and mounting
holes are not already present, bore drum pilot, allowing
a maximum of .004” clearance; and drill bolt holes,
using the hub as a template.
A
Axle
Figure 2-2
Checking Drum on Lathe
Install Flanges
If axle is equipped with brake mounting flanges suitable for installing electric brakes, clean flanges to
insure proper fit between flange and brake spider. If
axle is not equipped with flanges or old flanges are not
suitable for installing electric brakes, new flanges properly located - must be welded in position on the
axle. Cut off old flanges with a cutting torch leaving
axle clean and smooth.
Hub
B
Figure 2-1
Installing Drum on Axle
Install and Check Drum
Mount drum on hub and tighten securely. Check drum
for concentricity making certain that drum bore is concentric with axle spindle with .010” total indicator reading. Rotate drum on hub for best results. If drum is not
within concentricity limits, place hub and drum assembly in drum lathe (Figure 2-2) and remove the very minimum of stock which will permit drum to run within
concentricity limits. If it becomes necessary to remove
more than 1/32” from drum bore (diameter), remove
1/16” stock from drum and use oversized lining of
1/32” shim stock under lining to maintain proper drum
to lining clearance.
Select the correct brake mounting flange for the size of
brake to be installed.
#4604 for 15 x 3” brake
#40039 for 121⁄4 x 51⁄2” brake
#40039 for 161⁄2 x 5, 6, 7” brake
Mark the inside of the flange 1/16” larger than the actual size of the axle, (Figure 2-3). Cut the opening with a
cutting torch or turn out on a lathe. If opening in flange
is not large enough to permit assembly over axle collar,
cut flange in half with a hacksaw. Do not use a cutting
torch!
Mark 1/16”
larger than Axle
Saw Here
Figure 2-3
Installing New Mounting Flanges
Warner Electric • 800-825-9050 819-0514
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Kit 7494 Consists of:
Welding Fixture EQ-793
Mtg Accessory 111526
Shim
Axle
Flange
Welding Fixture
Bolted to Drum
Drum
Shim
Drum
Shim
Axle
Flange
Bolted To
Welding
Fixture
Kit 7494 Consists of:
Welding Fixture EQ-793
Mtg Accessory 111526
Shim
Axle
Flange
Axle
Flange
Welding Fixture
Bolted to Drum
Welding Fixture
Bolted to Drum
Drum
Shim
Drum
Drum
Drum
Shim
Shim
Shim
Shim
Shim
Axle
Flange
Bolted To
Welding
Fixture
Kit 7504 Consists Of:
Welding Fixture EQ-730
Mounting Acc. 11603
Kit 7494 Consists of:
Welding Fixture EQ-793
Mtg Accessory 111526
Shim
Axle
Flange
Axle
Flange
Welding Fixture
Bolted to Drum
Welding Fixture
Bolted to Drum
Drum
Shim
Drum
Drum
Drum
Drum
Drum
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Axle
Flange
Bolted To
Welding
Fixture
Axle
Flange
Bolted To
Welding
Fixture
Kit 7504 Consists Of:
Welding Fixture EQ-730
Mounting Acc. 11603
Welding Fixture Bolted
To Armature Adapter
Axle Flange
Weld
Armature
Adapter
Welding Fixture No.
EQ-615-A
Armature Adapter
Indentification
16½ x 5 - 21⁄64”
16½ x 6 - 53⁄64”
16½ x 7 - 1-21⁄64”
Bevel edges of hacksaw cut to provide surface for
good weld.
If a 16-1⁄2 x 5, 6, or 7” brake is to be installed, bolt
armature adapter to the drum, (Figure 2-4).
Adapter #3979 for 16-1⁄2 x 5” brake
Adapter #3993 for 16-1⁄2 x 6” brake
Adapter #3942 for 16-1⁄2 x 7” brake
It is important that a thin coating of “Permatex” or
other suitable sealer be used between armature
adapter and brake drum to prevent grease from leaking
under adapter and getting into brake assembly.
Figure 2-4
Bolting Armature Adapter to Drum
Figure 2-5
Location of Welding Fixture Inside of Drum
(12-1/4 x 5-1/2” Brake)
Figure 2-6
Location of Welding Fixture Inside of Drum
(15 x 3” Brake)
Bolt the welding fixture inside of drum as illustrated in
Figures 2-5, -6, -7.
Figure 2-7
Location of Welding Fixture Inside of Drum
(16-1/2 x 5, 6, 7” Brake)
Bolt axle flange to welding fixture and install hub,
Fixture #EQ-615A (Figure 2-7) for 16-1⁄2 x 5, 6, 7” brake.
Fixture #EQ-793 (Figure 2-5) for 12-1⁄4 x 5-1⁄2” brake.
Fixture #EQ-730 (Figure 2-6) for 15 x 3” brake. If clearance between drum and fixture is present, center the
fixture in drum by using shims between fixture and
drum in four locations as shown.
drum, and welding fixture assembly in place on axle.
Pull wheel bearing lock nut tight. If flange has been cut
in half, insert shims (Figure 2-8) in hacksaw cut before
welding to prevent shrinkage. If grease seal is used as
Warner Electric • 800-825-9050 819-0514
a bearing spacer and is too large for flange or welding
fixture to pass over, put welding fixture and flange on
axle and assemble to drum after hub and drum assembly are placed on axle. Center welding fixture in drum
by using shims as illustrated in Figures 2-5, -6, -7.
7
Shims
Figure 2-8
Location of Shims for Welding Flange
With an electric arc, tack both outer edges of hacksaw
cut, if cut is present. T
ack flange (Figure 2-9) to axle in
approximately four places. Complete weld by welding
hacksaw cut first - outer edge to axle - then make
continuous weld between flange and axle. Remove
bolts that hold flange to welding fixture and remove
hub, drum, and welding fixture from axle. Complete
weld on opposite side of flange. Remove welding
fixture from drum and clean all weld splatter from drum
or spindle surfaces.
Install Brakes
The desired position for mounting brakes on the axle is
indicated in Figure 2-10. Whenever possible they
should be mounted so that the brake spider anchor is
down and 45° to the rear as determined by forward
vehicle travel. Mounting brakes in this position affords
the best wheel bearing loading during application of
brakes. If the brakes are marked right and left hand
because of the type and location of lining segments in
brake shoes, the woven lining (with arrow indicating
drum rotation for forward vehicle travel) must always
be on the toe end of the shoe ring. Left and right hand
are determined by facing in the direction of forward
vehicle travel. In the event it is not possible to locate
the brake spider anchor as shown, the anchors must
be in the same relative location for all wheels.
For Brakes
Direction
of Travel
Marked Right
and Left Hand
Locate Woven
Lining on
Toe End
Tack Weld
Figure 2-9
Weld Points on Flange
NOTE: Do not use same hub and drum assembly as
template for all wheels. Use hub and drum
designated for each wheel location.
Brake
Spider
Anchor
45°
Figure 2-10
Brake Mounted in Correct Position
Install Armature in Drum
Bolt armature inside of drum (Figure 2-11). Armature
bolts directly to armature adapter for 16-1⁄2” series
brakes. On 12-1⁄4 x 5-1⁄2” and 15 x 3” brakes, grease
guard is placed between armature and drum when
armature is bolted in place. A thin coating of
“Permatex” or other suitable sealer must be used
between grease guard and drum at this time.
Warner Electric • 800-825-9050 819-0514
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