TM
TM
BrakeSafe
For Coaches w/Total Air
or Air Over Hydraulic Brakes
OPERATOR, PARTS
& INSTALLATION
MANUAL
BX88161, Push Cylinder, BrakeSafe
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.us
TM
TM
BRAKESAFETM is a proportional braking system that can be used on coaches with
Total Air or Air Over Hydraulic braking systems. With BRAKESAFETM you will use
your coach’s air brakes by tapping into the brake relay air source.
Locating Air Source On Coach
1. For coaches with total air brake systems, the brake relay is located ahead of the rear
axle. This relay has four to five ports, some of which will be used. There is a right and left brake
actuator hose coming from this relay, these hoses go to the brake actuators of each rear tire of
coach. There is a 3/8” O.D. pilot tubing coming from one of the four ports coming from the
brake relay. This is the SERVICE port that is the preferred place to connect into proportional air
that receives pilot air from the coach’s brake pedal. If this port has a 3/8” hose coming from it,
use the furnished tee fitting. Cut the tubing and push the tubing into each side of the tee fitting,
making sure the tubing is bottomed into the fitting. On the bottom of some relay valves there
are four ports, three are used, the other has a 1/2” pipe plug. Remove this plug and install the
furnished 1/2”pipe to 3/8” tube fitting. If your coach needs a fitting that is not supplied, most
hardware stores have brass pipe fittings. There should be no pressure coming from the port, unless the brake pedal is pushed down. If there is, you need to look for another port. Look at Fig.2
for a detailed schematic.
2. For coaches with
air over hydraulic braking systems, the air over hydraulic assembly is located
in front of front axle on the driver’s side. There is a drain plug on the bottom side of the air actuator, take this plug out and use the supplied tube connector. Look at Fig.3 for a detailed schematic.
3/8” Tubing Installation On Coach
3. Push the supplied 3/8” DOT tubing into the tee fitting or the pipe to tube fitting making sure it is
bottomed into the port. Route and secure the 3/8” DOT tubing with the 13” nylon ties supplied
making sure to route away from hot parts. There is 50 ft. of tubing supplied, which should be
plenty for most coaches. Once you get to the rear of the coach with the tubing, secure the mount
bracket with the 1/4” bolts, flat and lockwashers in a convenient location on the bumper. Make
sure it is the one with the larger hole. Then mount the bulkhead fitting, 3/8 tube fitting, and QD
coupler to this mount bracket as shown in Fig.7. Cut the extra 3/8” DOT tubing off and then
push into the pipe to tube fitting.
1/4” Tubing Installation On Towed
4. Unplug the QD plug and 1/4” bulkhead fitting from the self-coil hose assembly. If you have
a Blue Ox baseplate you can use the bracket plate to mount to your baseplate with existing
bolts. Then mount the QD plug and 1/4” bulkhead fitting to this bracket as shown in Fig.7.
If you have a baseplate other than a Blue Ox, you can use the other angle bracket
supplied. Mount this bracket with the 1/4” bolts, flat and lockwashers, and hex nuts to
your baseplate. Then mount the QD plug and 1/4” bulkhead to this bracket. Route the
1/4” tubing through the driver’s side engine compartment using the supplied wire ties,
making sure not to run tubing along hot parts. Push tubing through an existing
grommet through the firewall. If there isn’t a hole, drill a new hole. Continue
routing the tubing behind driver’s side kick panel, then under
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.us
292-5972 8/06 1 of 11
TM
Push-Cylinder Installation
5. Install the brake pedal arm mount bracket 3/4” above the brake pedal using the 1/4” x 1 1/4”
hex bolts, flat and lockwashers (See Fig. 6). Select a suitable location for the U-channel floor
bracket, preferably as close to the drivers seat as you can go, still being able to reach the brake
pedal. The bracket also needs to be in line with the brake pedal. IMPORTANT NOTE:
Before screwing the two pieces of the push cylinder assembly together, be sure to put the
o-ring in between them. The o-ring will be in the bolt bag. If this is not done, leaking
will occur. Then put in postion on brake pedal arm to get a location for the U-channel. Drill a
7/32” hole for the U-channel to be mounted. Loosen the 1/4” x 3/8” pan head screws and take
out the pivot mount assembly. Bolt the U-channel bracket on the floor with a 1/4” x 1 1/2” hex
head self tap bolt making sure the holes on the sides are towards the front. Replace the pivot
mount assembly with the 1/4” x 3/8” pan head screws. Be sure it pivots freely. Install the
cylinder assembly to the floor bracket by pushing the air coupler on to nipple. You will here a
click when they are attached. The clevis pin is not removed to install or remove the cylinder.
Adjust the length of push cylinder at the adjuster adapter by loosening the adjusting nut and
pull the cylinder assembly in or out to achieve the correct position. Make sure the adjusting
tube doesn’t slide. The total length should be a 1/2” shorter then the total length between the
brackets. Tighten the adjusting nut finger tight, then 2 and a 1/2 turns. This will ensure that
there is spring tension on the brake pedal, so it retracts back to its normal position shutting the
indicator light off in the coach.
Quick Exhaust Installation
6. Before plugging the 1/4” tubing into the elbow fittings, you must put the quick exhaust valve
in-line. Put the quick exhaust valve assembly one foot from the push cylinder by simply cutting the 1/4” tubing with a utility knife. Install the quick exhaust valve, making sure the little
hole is going towards the push cylinder assembly. The brake system will not operate correctly
installing the quick exhaust valve with the hole in the opposite direction. Also make sure the
tubing is pushed in all the way into the quick exhaust fittings. Push the end of the 1/4” tubing
into the cylinder pipe elbow. The door sill molding. End the routing under the driver’s seat,
making sure to leave enough to hook-up to the push cylinder. Cut the excess off.
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.us
292-5972 8/06 2 of 11
TM
INDICATOR LIGHT INSTALLATION
The BRAKESAFETM uses the towed vehicles brakes. Most vehicle’s brake lights work with the key in the off and in the accessory position. This creates the possibility of the towed vehicle’s battery being drained while towing as the brake lights are activated
each time the brake pedal is depressed by the BRAKESAFETM. Included are electrical parts which bypass the towed vehicles battery
while towing. The only change you will notice to the towed vehicle is that the brake lights will only be activated by the brake pedal
when the ignition is in the “on” position. We also include a light indicator that is installed in the dash of the towing vehicle which
lights up when the brake pedal in the towed vehicle is pulled on by the BRAKESAFETM. (Fig. 1) WARNING: Motorhome dash light
MUST be installed or warranty will be void.
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
1. Locate the brake light switch which is activated when the brake pedal is pressed down. Locate the hot wire into the switch and
the wire from the switch to the brake lights. You will need to splice into the wire coming from the switch to the brake lights. Cut
the wire at a convenient place and strip the two ends.
2. If there is room, you can locate the relay where you cut the wires. If there isn’t room, splice wires onto the ones you cut to give
yourself working room. Black wire and butt connectors are supplied in the parts sack.
3. Strip one end of the yellow wire and twist it together with the wire coming from the brake switch. Crimp a female spade terminal
on the twisted pair. Slide the terminal over the male terminal on the relay labeled “87”.
4. Crimp a female spade terminal on the end of the wire going the brake lights. Slide this terminal over the male terminal on the
relay labeled “30”.
5. Locate a bolt to use as a ground. Cut a piece of the black wire long enough to reach from the relay to the bolt. Strip both ends
of the black wire and crimp a ring terminal on one end and a female spade terminal on the other. Put the ring terminal under the
head of the bolt and the spade terminal on the male terminal on the relay labeled “85”.
6. In the car’s fuse panel locate a fuse that is “hot” only when the ignition switch is in “on” position. Use the mini fuse tapper with
fuse, crimp a female spade terminal on the end of black wire and attach it to fuse tapper. Cut a piece of black wire to reach from
the fuse to the terminal on the relay labeled “86”.
7. Route the yellow wire from the relay through the engine compartment of the car into the wiring disconnect plug. Then from the
wiring disconnect plug on the back of the coach along the bottom of the coach and into the dash of the coach. Tie the wire to the
frame of the coach with cable ties or other suitable means.
8. Locate a suitable place in the dash and drill a half (1/2) inch hole for the light indicator. Crimp a butt connector to both wires and
insert the indicator into the dash.
9. Cut the yellow wire to length and attach it to one of the wires on the indicator. Locate a bolt to use as a ground. Cut a piece of
black wire to length and connect it to the other indicator wire, crimp a ring terminal on the other end of the black wire and fasten
it to the grounding bolt.
10. Gather up the wires and the relay. Anchor them up out of the way so they will not interfere with driving the vehicle.
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.us
292-5972 8/06 3 of 11
TM
TESTING
The electrical installation can be
tested to see if it is installed correctly. When applying the brakes with
the key in the off and the accessory
position, the rear brake lights should
not come on, but when applying the
brakes with the key in the on position, the brake lights should come
on.
Figure 1
Testing Brake System
Connect the towed vehicle to the coach with towing system. Connect the self-coiling air line
to the coach and towed vehicle. Make sure the sleeve clicks forward on the QD coupler, this
will ensure the plug and coupler are locked. With the towed engine off, pump the brake pedal
several times to deplete vacuum or power boost in the towed vehicle’s power brakes. THIS IS
VERY IMPORTANT, AS OVER BRAKING WILL OCCUR IF NOT COMPLETELY DE
PLETED!! Start the coach engine and bring the air pressure up to pressure switch setting. Apply the coach brakes several times and witness the brake pedal movement in the towed vehicle.
Check that there are no leaks and that the cylinder in towed vehicle operates and releases
properly. Test drive the coach with towed vehicle attached on a hardtop road. Try the brakes
at several speeds above 50 MPH. You will notice the coach is stopping as if the towed isn’t
attached.
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.us
292-5972 8/06 4 of 11
TM
1. UNUSED RELAY PORT 2. TEE INTO BRAKE HOSE PORT
OPTIONAL SERVICE AIR SOURCES
AIR SOURCE FOR COACHES
WITH TOTAL AIR BRAKES
BRAKE PEDAL
PILOT AIR FROM
AIR SOURCE LOCATION,
CUT TUBE, INSTALL TEE
FITTING
OPTION 2
TOP PORT
NOTE:
IT IS IMPORTANT THAT ONLY SERVICE AIR BE TEED INTO.
ONLY TEE INTO RELAY VALVE PORTS OR TUBING THAT
HAS PRESSURE WHEN COACH BRAKES ARE APPLIED.
BRAKE RELAY
FIG. 2
AIR TO TOWED
BRAKE SYSTEM
PROPORTIONAL
TO RIGHT BRAKE ACTUATOR
MAIN AIR IN
TO LEFT BRAKE ACTUATOR
PROPRTIONAL PILOT AIR
AIR SOURCE LOCATION,
CUT TUBE, INSTALL TEE
FITTING
OPTION 1
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.us
292-5972 8/06 5 of 11
TM
NOTE:
AIR OVER HYDRAULIC
ASSEMBLY IS LOCATED
AHEAD OF FRONT AXLE,
ON DRIVER’S SIDE
WITH AIR OVER HYDRAULIC BRAKES
AIR SOURCE FOR COACHES
CONNECTOR
HYD. MASTERCYLINDER
FRONT
SUPPLIED TUBE
ONLY TAP INTO SERVICE BRAKE AIR. AIR SHOULD FLOW
FROM TUBE OR PORT WHEN BRAKE PEDAL IS APPLIED.
FIG. 3
REAR OF COACH
AIR ACTUATOR
MAIN PORT
BOTTOM DRAIN PLUG
RUN TUBING TO
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.us
292-5972 8/06 6 of 11
TM
U-CHANNEL
QUICK EXHAUST
AIR CONNECT &
FIG. 6
PUSH CYLINDER INSTALLATION
AIR CYLINDER WITH SPRING RETURN, LENGTH ADJUSTER, AND QUICK RELEASE
LENGTH ADJUSTER
ADJUSTING NUT
QUICK-RELEASE
BLUE OX
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.us
292-5972 8/06 7 of 11
BRAKE ARM BRACKET
TM
3/8” TUBE FIT-
TING
BRACKET
MOUNT
SELF-COIL HOOK-UP
FROM COACH
3/8” TUBE
3/8” BULKHEAD
QD COUPLER
(MALE)
3/8” SELF-COIL HOSE
BRACKET TO COACH
MOUNT ANGLE
FIG. 7
BRACKET PLATE
FRONT VIEW OF
QD COUPLER
(FEMALE)
QD PLUG
(10-3)
PLATE TO BASEPLATE
MOUNT BRACKET
1/4” BULKHEAD
FROM TOWED
1/4” TUBE
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.us
292-5972 8/06 8 of 11
Blue Ox Division, Automatic Equipment Mfg. Co. • One Mill Road, Industrial Park
TM
Pender, Nebraska 68047 • Phone 402-385-3051 • Fax 402-385-3360 • www.blueox.us
292-5972 8/06 9 of 11
TM
Parts List
Ref. No. Qty. Part No. Description
1 1 100-1118 ................................................................ Air Cylinder., 1.50 x 3.00, Mach.
2 1 293-1260 ........................................................................................ Adjuster Adapter
3 1 293-1262 ........................................................................................................ Sleeve
4 1 153-0085 ...............................................................................1/4 Nylon Tubing, 15 ft.
5 1 293-1263 .......................................................................................................Locknut
6 1 293-1264 ............................................................................................. Adjuster Tube
7 2 293-1323 .....................................................................................QD Coupler (3003)
8 2 293-1324 ..........................................................................................QD Plug, (10-3)
9 1 293-1268 ................................................................................................ Pivot Mount
10 1 293-1344 ................................................................................Pipe Elbow, (1/4-N2U)
11 1 293-1265 .............................................................................................. Floor Bracket
12 1 293-1267 ...................................................................................... Pedal Bracket, LG
13 1 293-1266 ......................................................................................Pedal Bracket, SM
14 1 62-3406 ........................................................................... Assy, Quick Exhaust Valve
15 1 293-1321 .................................................................................Tube Fitting, 3/8 x 1/4
16 1 293-1273 .................................................................................Tube Fitting, 3/8 x 3/8
17 1 293-1341 .....................................................................................................Tube Tee
18 1 293-1343 .................................................................................Tube Fitting, 3/8 x 1/2
19 1 105-1480 .....................................................................Angle, Mount Bracket, Coach
20 1 293-1320 ............................................................................. 3/8 P Bulkhead Adapter
21 1 293-1330 ......................................................................................Dust Plug, Rubber
22 1 293-1322 .................................................................................... QD Coupler, (3103)
23 1 293-1325 .......................................................................................... QD Plug, (11-3)
24 1 293-1318 ..................................................................................Air Hose, 1/4 x 10 Ft.
25 1 153-0086 .................................................................... 3/8 DOT Nylon Tubing, 50 Ft.
26 1 293-1319 ............................................................................. 1/4 T Bulkhead Adapter
27 1 105-1479 .....................................................................Angle, Mount Bracket, Towed
28 1 201-0671 .................................................. 1/4-20x 1 1/2 Hex Hd Self Tap Screw, ZP
29 1 201-0204 ............................................................. 1/4-20 x 1 1/4 Hex Bolt, Grd.5, ZP
30 2 201-0672 ............................................................... 1/4-20 x 3/8 Phillips Pan Hd., ZP
31 3 203-0001 ....................................................................................1/4 Flat Washer, ZP
32 3 203-0008 ....................................................................................1/4 Lockwasher, ZP
33 1 202-0001 ......................................................................... 1/4-20 Hex Nut, Grd.5, ZP
34 1 293-1261 ............................................................ O-ring, .875 OD x .75 ID
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.us
292-5972 8/06 10 of 11
TM
BRAKESAFE
TM
START-UP CHECKLIST
1. CONNECT TOWED VEHICLE TO THE COACH IN THE NORMAL WAY. IF BREAKAWAY SYSTEM IS USED, CONNECT LANYARD WIRE BETWEEN COACH AND
TOWED VEHICLE.
2. CONNECT THE SELF-COILING AIR LINE TO THE COACH AND TOWED VEHI
CLE. MAKE SURE THE SLEEVE CLICKS FORWARD ON THE QD COUPLER, THIS
WILL ENSURE THE PLUG AND COUPLER ARE LOCKED.
3. MAKE SURE ALL HOSES ARE PLUGGED IN, AND BOTTOMED INTO FITTINGS.
4. WITH THE TOWED ENGINE OFF, PUMP THE BRAKE PEDAL SEVERAL TIMES TO
DEPLETE VACUUM OR POWER BOOST IN THE TOWED’S POWER BRAKES.
IS VERY IMPORTANT, AS OVER BRAKING WILL OCCUR IF NOT COMPLETELY
DEPLETED!!
5. START THE COACH ENGINE AND BRING THE AIR PRESSURE UP TO PRESSURE
SWITCH SETTING. APPLY THE COACH BRAKES SEVERAL TIMES AND WIT
NESS THE BRAKE PEDAL MOVEMENT IN THE TOWED VEHICLE.
6. TURN IGNITION OF THE TOWED VEHICLE TO THE ACCESSORY POSITION, TO
UNLOCK STEERING WHEEL.
-
THIS
-
DISCONNECT CHECK LIST
1. DISCONNECT SELF-COILING HOSE AND TOW BAR FROM THE TOWED VEHICLE AND COACH. INSTALL PLUG AND CAP ON THE AIR DISCONNECTS, TO
KEEP WATER AND DIRT OUT OF THE SYSTEM.
2. DISCONNECT THE PUSH CYLINDER FROM THE BRAKE PEDAL.
THE TOWED VEHICLE IS NOW READY TO DRIVE AWAY.
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.us
292-5972 8/06 11 of 11
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