Blue Ox BX88144 User Manual

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BX88125 & BX88144

Serial No.

TOAD STOP

VAC BRAKE

Instructions for Supplemental Braking Systems.

BX88125 designed for gas powered Coaches. BX88144 designed for diesel powered Coaches.

THE FIRST NAME IN REMOTE BRAKING SYSTEMS

NOTICE: IF YOU ARE NOT AN EXPERIENCED MECHANIC OR INSTALLER, PLEASE REFER TO THE COMPLETE INSTRUCTIONS INCLUDED WITH VAC BRAKE

The ToadStop brake system applies a constant pressure to the toad vehicle's brake pedal, that can be adjusted to each individual toad vehicle.

Customer supplied tools & supplies

Razor knife, silicone spray lubricant, 12VDC tester, drill & bits: (1/8", 1/4", 5/8”), drill punch, wire stripper/crimp tool, pliers:(standard, long nose, wire cutter), screw drivers:(Phillips, slotted small & regular), wrenches:(10mm, 3/8", 7/8", 15/16", adjustable), 1/4" drive & 7/16"socket. Supplies: electrical tape, butt connectors, shielded spade connectors, wire ties, misc. screws, hose adapters (for our 3/8" vacuum hose, supplied, to your size on the RV or Toad).

INSTALLATION INSTRUCTIONS

1. TOAD VEHICLE INSTALLATION MECHANICAL INSTALLATION OF COMPONENTS: Fig. 1

a. Remove rubber pedal cover and drill 1/8” hole in the face of the brake pedal frame at its lowest point. For vehicles with continuous power assist

brakes, do not drill into brake pedal frame. Use brake pedal assembly (item 8) above the brake pedal frame. The lower the assembly is placed

on the pedal frame, the more force that is applied. In the unlikely event more force is needed, drill the hole in the brake pedal frame. b. Mount the cable pulley on the ﬂ oor behind the brake pedal with two self drilling screws provided, aligning the cable for the most efﬁ cient pull back. c. Mount the vacuum actuator in a suitable place under the hood in the engine compartment with 13" cable ties. Making sure to position actuator box

so that the docking slot is facing towards the driver's side. (Locate unit away from hazards and hot spots.) d. Route the cable housing through an existing hole through the ﬁ rewall, or if a hole cannot be found, drill a 3/8" hole through the ﬁ rewall and push the

3/8" grommet in place. If the grommet is used, the docking ﬁ tting that is on the cable assembly, will need to be removed for the cable housing to go

through. Reattach the docking ﬁ tting once the cable housing is pushed through, then slide the cable through the housing, making sure the ball end

is towards the docking ﬁ tting. e. Attach the docking ﬁ tting to the actuator box and replace the plastic plug to secure the ﬁ tting. Remove the box top and attach the cable end to the

hole on the end of the pull arm. Replace the plastic plug that goes on the pull arm, so the cable end will not slip out. f. Pull the cable through the hole on the brake pedal removing all slack. Push the cable stop up to the brake pedal and tighten.

TOAD VACUUM HOSE INSTALLATION: Fig. 2 & 4 - For vehicles with continuous power assist brakes, do NOT perform steps C

and D.

a. Install two 3/8” hose barb ﬁ ttings and one threaded plug to the vacuum reservoir and place it in a suitable area in the engine compartment (locate

unit away from hazards & hot spots). b. Cut a piece of vacuum hose long enough to attach to one hose barb ﬁ tting on the reservoir to the hose barb ﬁ tting on the vacuum actuator box. Cut

this hose and install a plastic vacuum tee as shown in Fig.2. c. Remove the vacuum hose from the original power booster check valve of the towed brake system, place the kit check valve and “T” assembly in

this line, with the black side facing away from the power booster and towards the engine vacuum ﬂ ow. Fig.2 & 4 d. Install the vacuum hose from the remaining push on ﬁ tting of the reservoir to the “T” connection in previous step.

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TOAD WIRING INSTALLATION: Fig. 7 & 10

a. Connect one wire from the Vac Brake® solenoid to a suitable ground. (either wire) b. Install the dash switch in an inconspicuous and easy to reach place, on the center of the dash, to the right of the driver. c. Connect the remaining wire of the solenoid to the middle pin of the dash switch. Fig. 10 d. Connect an ignition “HOT” 12VDC feed wire to the terminal on dash switch as shown in Fig. 10.

e. Connect a 12VDC feed a wire from a constant 12VDC source to the remaining terminal on the dash switch. Fig.10

BASIC OPERATION SETUP AND PRELIMINARY TUNING BEFORE RV INSTALL

TEST WITH VEHICLE “RUNNING” AND VACUUM PRESENT IN THE SYSTEM FROM TOAD ENGINE.

Adjust the pedal speed by turning the solenoid "AE" and "BE" ports "clockwise" until all the way "seated" closed. Fig 5 There should be no action, when ﬂ ipping dash switch, with the ports turned clockwise and seated. Next turn the "AE" port ½ turn "out", then turn the "BE" port out all the way. This should result in faster "pull down" and "slower release" of the brake pedal action. Adjust to the desired skill level of pedal movement with ¼ turns on each port. You can now drive and test the system, by ﬂ ipping the dash switch to stop

the vehicle while moving with the Vac Brake®. Test at idle speed ﬁ rst, then increase speed.

TESTING AND TUNING THE SYSTEM ON THE TOAD

CAUTION: ALWAYS PERFORM THIS TEST IN A SAFE CLEAR AREA. ALWAYS BE PREPARED TO USE YOUR FOOT TO STOP THE TOAD VEHICLE DURING TESTING.

a. Start the engine of the toad vehicle, making sure that the Vac Brake® does not apply. If the Vac Brake® applies, verify the toggle switch is in center

position.

b. Push the toggle switch to the momentary position and this should apply the Vac Brake®. Releasing the switch should release the Vac Brake®.

Note: (Especially on Jeeps) To get a true braking test on the toad vehicle, once up to speed (10-20 mph) shift from drive to neutral, then press and hold the toggle switch to the momentary position. The vehicle should have a steady braking pressure being applied. When the vehicle comes to a stop, put the vehicle in DRIVE, give it a little throttle and let off. The vehicle should move forward as you give it throttle, and stop when you let up.

c. To balance Vac Brake® power, repeat the test in step b. moving the pedal bracket cable attachment up or down to compensate for to much throttle

or to little throttle, respectively, needed to move the vehicle. Each inch up decreases power by 10%, down increases power 10%.

THIS UP & DOWN LEVERAGING OF THE CABLE CONNECTION POINT IS THE STRENGTH ADJUSTMENT. Fig 1

d. Vac Brake® application speed is adjusted with two needle valves built into the Vac Brake® solenoid. The “AE” needle valve controls the speed

of Vac Brake® release; “BE” needle valve controls the speed of Vac Brake® engagement. We recommend the release be slower than the engagement. THIS VACUUM FLOW ADJUSTMENT CONTROLS BRAKE APPLICATION SPEED AND RELEASE SPEED. Fig. 5

e. To test the anti-theft toggle, turn off the engine. Flip the toggle to the engaged position (off center, and will stay when you remove your ﬁ nger).

Start the engine, and the Vac Brake® should apply itself.

Automotive Relay Note: If the towed vehicle's brake lights will work with the key off, there is a possibility that the towed vehicle's

battery may be drained after towing as the brake lights will be activated each time the brake pedal is depressed by the ToadStop. To keep this from happening we have included electrical parts (relay) with the kit to automatically disconnect the vehicle's brake lights when the key is off. The only change you will notice to the towed vehicle is that the brake lights on the car will only be activated by the brake

pedal when the ignition is in the "on" position.

FINISHING ELECTRIC AND VACUUM CONNECTIONS TO THE FRONT OF TOAD VEHICLE (Fig. 10)

a. (RECOMMENDED) When using the relay, cut the brake wire that is HOT when the brake pedal is applied. Connect a wire from the end of the

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wire that is closest to the brake switch to tab 87 on the relay, making sure to connect with a wire that goes to the wiring connector on the front of the

vehicle. Then connect a wire from the other end of the cut wire to tab 30 on the relay. Connect a wire from the car's fuse panel (12V IGNITION) to

tab 86 on the relay. Tab 85 needs to go to a good solid ground connection. When NOT using the relay, connect a wire from the wiring connector to the "cold" side of the brake switch. b. Install the breakaway switch to a central location on the towed vehicle's metal frame structure (do not install to the baseplate or any additionally

installed item) on the front of the toad vehicle. c. Connect one wire from the breakaway switch to the positive terminal of the battery or other constant 12VDC source. d. Connect the other wire from the breakaway switch to the activation feed wire circuit of the solenoid on the Vac Brake®. Then route a wire from the

green wire of the four wire connector to an open pin on the wiring connector on the front of the vehicle. e. Mount the bulkhead ﬁ tting with 3/8” push-on ﬁ ttings on the back side, utilizing the supplied bracket, as close to center of the vehicle as possible.

The baseplate is a preferred location to mount the bulkhead. Fig. 2 f. Install the vacuum hose from the back of the previously installed bulkhead ﬁ tting and route it to the Vac Brake® vacuum plumbing using the plastic

vacuum “T” with the check valve oriented so that the black side is towards the bulkhead. Fig. 2 g. Install hose clamps at each vacuum ﬁ tting installed on vehicle for extra vacuum holding power.

2. RV INSTALLATION : VACUUM CONNECTION: Fig. 6 & 7

a. Verify that the 3/8” push-on connector is attached to the back side and the male quick-connect is on the front side of the bulkhead. At the rear of

the motorhome using the included bracket, mount the bulkhead connector assembly, making sure to keep it as close to center as possible. Make

sure all bulkhead assembly connections are tight. b. IGNORE THIS STEP IF YOU HAVE A DIESEL ENGINE. Locate a vacuum source on the intake manifold of the motorhome engine. Generally you

will utilize a plugged port directly in the engine manifold, or use a plastic tee to splice into an existing primary manifold vacuum line (do not use a

vacuum line connected to engine function devices).

c. Route vacuum line from the vacuum source to the backside of the bulkhead at the rear of the RV.

VACUUM PUMP OPTION FOR DIESEL RV OR DEDICATED VACUUM SOURCE: Fig. 7

a. Find a suitable location for the vacuum pump, generally in the rear engine compartment of the RV, close to an ignition controlled power source. b. Route vacuum hose from the push-on connector of the pump to the rear of the bulkhead located at the back of the motorhome. c. Use the black wire on the pump and connect it to a good grounding point on the chassis of the motorhome. d. Use the red wire on the pump and connect it to a 12 VDC ignition controlled power source. Pump will run continuous when RV is started (use a

male/female shielded spade connector to disconnect power if not towing).

RV WIRING: Fig. 8 and 9

WARNING: WHEN INSTALLING THE INDICATOR LIGHT IN THE MOTORHOME, DO NOT DRILL A HOLE

DIRECTLY IN THE COACH'S DASH. Drilling a hole directly in the dash of the coach could cause serious

damage to the on-board computer systems. This applies to all makes of motorhomes, but is especially

pertinent for Bluebird motorhomes. Alternate methods for installing the indicator light are as follows: Drill the hole lower in the bordering plastic of the dash

Drill the hole to the left of the driver's stall if there is room Use a toggle switch mounting bracket from a local automotive store

a. Locate an easy to reach, driver visible place for the lighted remote control switch to be installed on the RV dash. b. Looking at the back of the switch, with the row of three terminals oriented towards the top, connect the monitor

signal wire (from the TOAD’S brake light switch) to the lower right terminal. The lower left terminal is to be connected to a

suitable grounding point.

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c. Connect a wire from the cold side of the RV’s brake light switch to upper left terminal of the switch. d. Connect a wire from a constant 12 VDC power source (generally from the fuse panel) to the upper right terminal of

the switch. e. Connect the center terminal of the RV dash switch to a wire that runs to the RV wire receptacle on an unused pin,

across the tow bar to the activation signal wire of the solenoid on the Vac Brake®.

TESTING THE VAC BRAKE® WITH THE RV

THE VACUUM HOSE MUST BE CONNECTED BETWEEN THE VEHICLES TO TEST THE SYSTEM. CONNECT THE ELECTRICAL WIRE HARNESS AND THE VACUUM HOSE ACROSS THE TOW BAR.

a. The RV dash remote control switch is to be ﬂ ipped ON during this test (ﬂ ipped off center, and remains in place when you remove your ﬁ nger). With

the RV running, depress the brake pedal, noticing that the dash switch should light up as the brake is applied, and go off slightly after releasing the

pedal. b. Repeat the test above with the switch ﬂ ipped OFF (ﬂ ipped center, and remains in center place when you remove your ﬁ nger). The dash switch

should not light up, nor should the Vac Brake® apply. c. The third test is to press the paddle of the switch to the momentary position. The switch should light up, as well as the brakes of the toad apply.

The light should go out and the Vac Brake® should disengage after releasing the switch. d. Pull the breakaway pin and check to see that the Vac Brake® activates, and then releases as you re-insert the pin in the breakaway switch. The

RV dash switch should also light to indicate braking in the toad.

THIS SYSTEM PROVIDES FULL DRIVER FEEDBACK AND CONTROL

WARNING: You are responsible for monitoring the “FEEDBACK LIGHT” on the RV dash switch. If the switch light does not “LIGHT” during

normal application of the brake in the RV, there is a problem that you MUST investigate! If the switch light does not “GO OFF” during release of the RV brake, there is a problem that you MUST investigate! (a slight delay as the pedal releases is normal for the operation of this system, this is just the regulated release speed as the pedal returns to full released position) If the light comes “ON” by itself you must “STOP” and investigate the cause, it may be that the “BREAKAWAY PIN” HAS PULLED DUE TO A

TOW COMPONENT FAILURE.

TROUBLE SHOOTING

If the Vac Brake® worked properly during the tests of the TOAD alone and not with the RV, double-check your vacuum source and electrical connections making sure the harness terminals align properly between vehicles. Make sure vacuum check valves are allowing the vacuum to ﬂ ow in the correct direction.

System will not activate from RV. Check the “ground” between vehicles, (system uses only ½ amp to activate) and the lighting ground between the

vehicles may not be good enough for the Vac Brake® system to get ground. A better ground from the Vac Brake® solenoid may be needed (closer to the lighting ground wire between vehicles).

System will not release from RV. Check for a “12VDC backfeed” to the activation wire on the solenoid. Isolate and add diode or change wiring to eliminate the “12VDC backfeed” condition. Pulling apart the wire harness between the vehicles should release the Vac Brake®. Also check to be sure the “breakaway” switch is not triggering the system.

Feedback light on RV dash does not light. Make sure all connections between vehicles are correctly made between corresponding terminals at the wiring plugs on both vehicles. Test for power feed along all wiring between vehicles.

System will not pull pedal and stop satisfactorily. Check vacuum level in system during operation with a vacuum gage (18”-20”vacuum needed to work). Check for vacuum leaks by shutting down engine with gage on and see if vacuum holds. Levering the cable attachment down the pedal can compensate for lower vacuum level and make stopping force “STRONGER”. Check to be sure there are no ”SHARP” turns on the cable housing between the pedal and device. NOTE: this system can only deliver braking as good as is provided by the vehicle, if ﬂ uids in brake system have not been serviced every two years as recommended, it may effect ﬁ nal performance. Cable must slide freely in housing, check to be sure there are no kinks by sliding cable back and forth to feel for internal drag.

Brake system adjustments after brake service. None should be required unless the driver wants to change performance from the original installation. You can install new brakes on your vehicle immediately after this system is installed, and the performance will not be effected.

© 2005, 06, 11 Blue Ox Division, Automatic Equipment Mfg. Co. • One Mill Road, Industrial Park Pender, Nebraska 68047 • Phone 402-385-3051 • Fax 402-385-3360 • www.blueox.com Page 4 of 10 292-5809 Rev. C 2/21/11

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SIZING THE VACUUM HOSE AND ELECTRICAL CONNECTIONS ACROSS TOW BAR

a. With the toad vehicle connected to the tow bar, ﬁ nd the minimum length of the breakaway lanyard by measuring from the anchor point on the RV (as close to center as possible) to the breakaway switch. Record this measurement as X=

b. Find the maximum length of the breakaway lanyard by disconnecting the tow bar and leaving the tow cables connected. Slowly back up the toad

until the cables capture it. Apply the parking brake, and turn off the engine. Make the same measurement as in step a. Record this measurement

as Y= c. To ﬁ nd the length of the lanyard to be used take the measurements (X) and (Y), add them together, and divide by 2, (X+Y)/2=Lanyard Length

NOTE THE LANYARD LENGTH MUST BE LONG ENOUGH TO PERMIT TURNING WITHOUT PULLING THE PIN WHEN TOWING. THE ABOVE SIZING PROCEDURE ALLOWS THE BREAK AWAY PIN TO PULL AND APPLY Vac Brake™ TO HELP CONTROL THE TOAD VEHICLE WHEN IT FALLS BACK ON THE SAFETY CABLES OR CHAINS.

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Pender, Nebraska 68047 • Phone 402-385-3051 • Fax 402-385-3360 • www.blueox.com Page 6 of 10 292-5809 Rev. C 2/21/11

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RV BRAKE SWITCH

RV FUSE PANEL

(CONSTANT)

LIGHTED

SWITCH

RV DASH

CONNECTION

ACROSS TOWBAR

BREAK

AWAY

SWITCH

TOAD

BRAKE

SWITCH

TOAD

BATTERY

FUSE PANEL

GROUND

12 VOLT

CONSTANT

TOAD SIDERV SIDE

TOW

ANTI-

THEFT

"ON"

UNLIGHTED

SWITCH

MOM.

TEST

12 VOLT

FROM

IGNITION

CAR FUSE

PANEL

(IGNITION)

SYSTEM WIRING DIAGRAM

RELAY

CUT BRAKE WIRE THAT IS HOT

WHEN BRAKE IS APPLIED

FIG. 10

VEHICLE BRAKE LIGHTS

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IMPORTANT: Use only genuine factory replacement parts on your braking system. Do

not substitute homemade or nontypical parts. If parts are lost or in need of replacement, for your safety and the preservation of your braking system. Order replacement parts through your nearest Blue Ox dealer or distributor.

Parts List

Ref. No. Part No. Description

1 62-3474 ............................................................................................Assy, Box, Small, TS

2 293-1404 ...................................................................................................Vac Pump, TSII

4 62-3476 .............................................................................................Assy, Bulkhead, Tow

5 62-3475 .........................................................................................Assy, Bulkhead, Towed

*6 62-3463 ...................................................................................................Assy, Hose, TSII

7 62-3479 ..................................................................................................Assy, 6 FT Cable

8 62-3472 .................................................................................................Assy, Brake Pedal

9 293-1339 ..............................................................................................Breakaway Switch

10 62-3477 ................................................................................Assy, Female Quick Connect

11 293-1370 ..................................................................................................... Vac Reservoir

12 153-0105 .................................................................Tubing, 3/8 ID x 5/8 OD x 600 Inches

13 102-6275 ...........................................................................................Flat, Bracket, Toggle

14 102-6276 ...................................................................................... Flat, Bracket, Bulkhead

15 293-1375 .........................................................................................Lighted Toggle Switch

16 293-1376 ..................................................................................... Unlighted Toggle Switch

17 294-0729 ...............................................................................................Relay, Automotive

18 293-1425 ............................................................................................................L-Bracket

19 293-1426 ................................................................................................... Bracket, Mount

20 293-1417 ...................................................................................Hose Barb, 3/8" Push-On

21 293-1367 ........................................................................................................Check Valve

22 293-1437 ..........................................................................................................Hex Nipple

23 293-1393 ...........................................................................................Male Quick Connect

24 293-1368 ...........................................................................................Bulkhead, 1/8 FNPT

25 293-1384 ............................................................................................ Plastic Vacuum Tee

26 153-0095 .............................................................................Hose, 3/8 ID x 5/8 OD x 2 1/2

27 293-1418 .................................................................................................. Plug, 1/8 MNPT

28 293-1405 ................................................................................................Grommet, Plastic

*29 293-1388 ........................................................................................................Hose Clamp

30 293-1436 ..................................................................................................Plastic Plug, .41

31 194-0149 ...........................................................................Wire, 18 GA, Blue, 780 Inches

32 194-0150 ...................................................................... Wire, 18 GA, Orange, 780 Inches

33 201-0708 ......................................................................#10-32 x 1 1/2 Self-Drilling Screw

34 202-0001 .............................................................................................1/4-20 Hex Nut, ZP

35 290-0159 ...............................................................................................Cable Tie, 13 Inch

36 201-0705 ...........................................................................1/4-20 x 1 Carriage Bolt, Grd.5

*These parts are not used on vehicles with continuous power assist brakes.

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Pender, Nebraska 68047 • Phone 402-385-3051 • Fax 402-385-3360 • www.blueox.com Page 10 of 10 292-5809 Rev. C 2/21/11

Blue Ox BX88144 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual