Blue Ox BX88175 User Manual

BX88175 Installation Instructions

Serial No.

ToadStop II Vacuum Brake System

Customer supplied tools & supplies

Utility knife, 12VDC tester, drill & bits: (1/8", 1/4", 5/8”), ¼” socket drive bit, 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.

INSTALLATION INSTRUCTIONS

1. TOAD VEHICLE INSTALLATION

MECHANICAL INSTALLATION OF COMPONENTS: See Fig. 1

a. Remove rubber pedal cover and drill 1/8” hole in the face of brake pedal frame at its lowest point. If there

is too much pulling pressure at this point, use brake pedal assembly (item 24) above brake pedal pad.

For vehicles with continuous power assist brakes, do NOT drill into brake pedal frame. Use brake

pedal assembly (item 24) above the brake pedal frame. The lower the assembly is placed on the pedal

frame, the more force that is applied.

b. Decide where to locate the blue box. The cable assembly is 15 ft. long so the box can be mounted in

the trunk. The box can also be mounted behind the driver's seat. If this location is preferred, the cable assembly will need to be cut and modi ed. Set the box where you would like it when towing. Lay the cable assembly on the  oor, placing the pulley end straight behind the brake pedal as shown in Fig. 1. Measure the distance the cable housing extends past the box. This is how much will need to be cut off of cable housing. Take the cable stop off of cable. Pull the cable housing off of the knurled  tting that is mounted to the pulley. Slide the 1" adapter tube and 1/4" long tube off of cable housing. Pull the cable out of the cable housing and mark out the previously measured distance on the housing and cut. The metal winding in the housing may have to be sanded down. Mount the cable housing back onto the knurled  tting on the pulley. Route the cable through the housing and replace the cable stop. Cut the cable, making sure the cable is about 12" longer than the housing. Locate a mounting point for the pulley behind the brake pedal on  rewall. (Align the pulley trailing side straight behind pedal arc for a good straight pull of the pedal) Fig.1

c. Using two self-tapping screws, mount the pulley to the  rewall. Run the cable housing under the  oor mat

or customize routing under carpet and dock plastic end to box. (Fig.4, Fig.1) d. Connect cable ball in the center position on the pull arm in the box. Fig. 4 e. Attach the cable at the brake pedal with cable stop, making sure there is no play in the cable, then make

adjustments testing.

TOAD VACUUM HOSE INSTALLATION: See Fig. 3 - For vehicles with continous power assist brakes

do NOT perform the "toad vacuum hose installation" steps . Simply connect ToadStop II to kit

reservoir via hose (see Fig.3) for these vehicles.

a. Remove the original vacuum line from the booster check valve and install the “check valve/T” assembly

to the booster check valve as shown in Fig. 3 (install original vacuum line to “black side” of kit check valve

assembly) b. Find an existing hole in the  rewall, or if there isn't one, drill a 5/8" hole and mount bulkhead. Tighten the

3/8" hose barbs on each side. Use hose clamps that are provided on all hose connections. Route the

vacuum tube to the  rewall bulkhead connection and into drivers compartment to mate with box at vacuum

quick connect.

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292-5958 10/07 Page 1 of 10

c. If your vehicle has ½” ID hose, adapt to 3/8” or use clamps to “squeeze” the ½”

down securely to 3/8”  ttings. Use the clear vinyl spacer hose to adapt up to ½” OEM size if needed.

TOAD VACUUM HOSE INSTALLATION (continued)

d. Cut the vacuum line installed in the previous step, insert “T” and connect reservoir to the system between

our new check valve and the booster check valve.

TOAD WIRING INSTALLATION: See Fig. 2

a. The box is equipped with a four wire  at connector that uses the following connection sources.

1.White connects to GROUND.

2.Brown connects to BATTERY 20amp fused source.

3.Yellow is NOT USED.

4.Green connects to RV COLD SIDE BRAKE LIGHT SWITCH. NOTE: There are two diodes supplied in case there is "electrical feedback". Most of electrical feedback

problems are "bad grounds". Be sure to check all grounds, before installing diodes. Check original car wiring & wiring kit wiring for bad grounds.

b. The orange and blue wires feed between both vehicles at the trailer wiring connector, using two spare pins

in the wiring plug connector (if spare pins are not available, upgrade the customer to a higher capacity connector).

c. Install the breakaway switch to a central location on the front of the towed vehicle's metal frame structure

(do not install to the baseplate or any additionally installed item) and attach the lanyard to the

receiver hitch on the rear of the RV. d. Connect one wire from the breakaway switch to the positive terminal of the battery. e. Connect the other wire from the breakaway switch to the Green wire feed to activate braking during

breakaway.

EMERGENCY/ANTI-THEFT SWITCH OPERATION (See Figure 2 for wire hook-up.)

a. The unlighted dash switch for the operation of the box while driving is an accessory that can provide

emergency braking while driving with the simple  ip of a switch, if something happens to the driver. It will

also provide anti-theft protection while towing or parked during solo driving. b. To test emergency stopping while driving, apply braking by  ipping the dash switch to activate brakes and

stop the vehicle (on some vehicles, it may be necessary to shift to neutral to stop, if a high idle condition is

present). c. To test the anti-theft mode, turn off the engine. Flip the toggle to the “ON” position (off center, and will stay

when you remove your  nger). Fig. 2 Start the engine, and the brake system 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 CONNECTIONS TO THE TOAD VEHICLE (Fig. 2)

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 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

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292-5958 10/07 Page 2 of 10

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.

TESTING AND TUNING THE SYSTEM

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 breakaway pin is inserted in the breakaway switch.

b. Push the box test BUTTON to the momentary position and this should apply the Vac Brake™. Releasing

the BUTTON should release the Vac Brake™. With the vehicle in drive, and moving at idle speed, apply the Vac Brake™ with the test BUTTON held “ON”. When the vehicle comes to a stop give it a little throttle and let off. The vehicle should move forward as you give it throttle, and stop when you let up (you will have to hold the test BUTTON during testing of brake strength) Fig. 4

c. To balance and adjust Vac Brake™ braking strength, repeat the test in step b. moving the cable ball

connection along the box arm bracket “in towards the pivot point for stronger braking” or “out from the pivot point for less braking” this compensates for to much throttle or to little throttle, respectively, needed to move the vehicle. THIS “IN AND OUT” LEVERAGING FROM THE PIVOT POINT ON THE BOX ARM IS THE STRENGTH ADJUSTMENT Fig. 4

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. SPEED IS FACTORY SET WITH MINOR ADJUSTMENTS DONE BY THE INSTALLER AS NEEDED. RELEASE SHOULD BE SLOWER THAN PULL DOWN SPEED. Fig. 5

2. RV INSTALLATION - RV WIRING: Fig. 2 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 place for the remote control RV dash switch to be installed. 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

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