Blue Ox BX8894 User Manual

TO BE VALID, WARRANTY CARD MUST BE COMPLETED IN ITS

ENTIRETY BY AN AUTHORIZED DISTRIBUTOR OR DEALER AND SENT

TO AUTOMATIC EQUIPMENT MFG. CO., PENDER, NEBRASKA. FAILURE

TO DO SO WILL VOID THE WARRANTY.

Product Safety Policy Statement

It is, and shall continue to be, a primary objective of Automatic Equipment Manufacturing Company
to provide customers with safe and reliable products. Automatic will, and has, established safety
procedures in product design, manufacture, promotion and sales; and will coordinate efforts to promote
customer safety to the greatest extent possible. Each department has primary responsibility for the
promotion of safety under the guidelines of the Product Safety Committee.

292-2215 7/02

BX8894, BX88100

TM

AutoStop

Automatic Equipment Mfg. Co.

One Mill Road, Industrial Park l Pender, Nebraska 68047

BX8894

TM

AutoStop

BX88100

OPERATOR, PARTS

& INSTALLATION

MANUAL

BX8894, BX88100 AutoStop

TM

TOWING PRODUCTS DIVISION

REPLACEMENT PARTS

Parts List

Ref. No. Qty. Part No. Description

1 1 62-3161 ............................................................................... Receiver Cable Assembly

2 1 202-0047 ................................................................................................ 10-32 Hex Nut

3 1 201-0192 .....................................................................10-32 x 1/2 Round Head Screw

4 1 202-0110 ..................................................................................... 7/16-20 Hex Jam Nut

5 1 299-0259 .............................................Ball Mount, Spring Autostop, Chrome, BX8894

6 1 229-0369 ....................................................................................Rod, 5/8 x 2, Autostop

7 2 229-0356 ................................................................. Pulley, Shock Absorber, Autostop

8 1 299-0382 ......................................................................Flat, Spacer, Narrow, Autostop

9 1 299-0384 ............................................................................... Bushing, Front, Autostop

10 1 207-0842 ....................................................................................Cap, Spring, Autostop

11 1 222-0076 ................................................................................Spring, Comp., Autostop

12 1 299-0385 ................................................................................Bushing, Rear, Autostop

13 1 229-0354 .......................................................................Pulley, Narrow Rear, Autostop

14 1 299-0289 .........................................................................Flat, Pulley Divider, Autostop

15 1 299-0383 .........................................................................Pulley, Front, Med., Autostop

16 1 299-0286 .................................................................................Cable Anchor, Autostop

17 1 201-0150 .....................................................................1/4-20 x 3/8 Knurled Set Screw

18 1 294-0811 .................................................................................5/16 Metal Cable Clamp

19 1 299-0277 ......................................................................M H Universal A-Stop, Chrome

20 1 299-0255 .......................................................................... Nut, Adjusting, Autostop, ZP

21 1 299-0256 ..........................................................................Bolt, Adjusting, Autostop, ZP

22 1 201-0366 ........................................................... 7/16-20 x 2 1/4 Hex Head Bolt, Grd. 5

Parts not shown:

Ref. No. Qty. Part No. Description

23 2 225-0052 ......................................................................................Clip, 3/32 Wire Rope

24 1 229-0362 ..................................................................................3/32 SS Cable Thimble

25 1 229-0363 ...............................................................................Ring Detent Pin, 3/16 x 1

26 3 294-0811 .................................................................................5/16 Metal Cable Clamp

27 3 201-0192 .....................................................................10-32 x 1/2 Round Head Screw

28 3 202-0047 ................................................................................................ 10-32 Hex Nut

29 1 290-0324 ...................................................................................Red Cap, .207 ID x 3/4

30 2 294-0250 .............................................................................Butt Connector, 16-14 Ga.

31 3 294-0187 .............................................................Ring Terminal. 5/16 Stud, 16-14 Ga.

32 8 294-0518 ................................................................Term. Coupler, Female, 16-14 Ga.

33 1 294-0813 .................................................................................................Indicator Light

34 1 294-0729 ...........................................................................................Automotive Relay

35 1 62-3366 .......................................................................Brake Cable Assembly, Coated

36 1 194-0140 ........................................................................65 Ft Coil 16 Ga. Yellow Wire

37 1 194-0139 ...................................................................................4 Ft 14 Ga. Black Wire

38 4 290-0159 ........................................................................................13" Nylon Cable Tie

39 2 290-0131 ....................................................................................5 7/8" Nylon Cable Tie

40 1 101-6377 ...................................................................... Bracket, Cable Housing Mount

41 1 201-0050 .................................................................... 1/4-20 x 3/4 Hex Bolt, Grd.5, ZP

42 1 202-0001 ............................................................................................... 1/4-20 Hex Nut

43 1 203-0008 .....................................................................................1/4 Lock Washer, ZP

44 1 203-0001 ........................................................................................1/4 Flat washer, ZP

45 1 294-0807 ........................................................................................... Mini Fuse Tapper

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REPLACEMENT PARTS

CABLE ROUTING

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initial setting, adjust to your driving preference if
needed. The location of the adjusting nut is shown
in Figure 23. The initial preload ranges are listed in
Figure 24.

10. Once you have the cable wrapped properly, pull
slowly on the other end of the cable while holding
the pulleys and swage in place with the other hand
to prevent the cable from unwrapping. Keep tension
on the cable and slide the pulleys into the AutoStop
tube. (Figure 20) When the second set of pulleys
start into the tube, stop and remove the 5/8 rod.

ASSEMBLY INSTRUCTIONS

11. Pull slowly on the cable until the holes in the
second set of pulleys line up with the holes in the
end of the AutoStop tube and insert the 5/8 rod.

12. With the AutoStop still on its side, be sure that the
pulleys, cable anchor, and pulley divider are all
together and pressed down to the side of the tube.
Place a 20 thousanths inch (.020") feeler gauge
between the cable anchor and wide pulley and
tighten the set screw in the end of the cable anchor.
(Figure 21) NOTE: Be sure to keep the

5/8 rod centered in the AutoStop tube while
tightening the set screw.

Figure 20

Figure 21

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ASSEMBLY / ADJUSTING INSTRUCTIONS

Figure 18

6. Set the wide pulley on top of the pulley divider. It is
symetrical so it can be put on either way. (Figure

16) Set the cable anchor on top of the wide pulley
with the groove facing you and the notch out of the
corner to your right. (Figure 17)

7. Set the movable pulley assembly next to the
AutoStop tube, and next to it place the stationary
pulley assembly.(Figure18) You are now ready to
route the cable around the pulleys.

8. Pull the cable through so you have all the slack at
the back where you will be wrapping the cable. The
AutoStop tube should still be positioned with the
tongue flat side towards you. (Figure 18)

9. Refer to (Figure 19) while wrapping cable around the
pulleys. The cable should protrude from the
AutoStop tube at the lower corner of the tongue flat
side facing you. From here, route the cable in front
of pulley "A" and counterclockwise around pulley
"B". Continue on the back side back to pulley "A"
and go around it counterclockwise also. From here,
route the cable around pulley "C" counterclockwise
then pulley "D" counterclockwise. Lay the cable in
the groove in the cable anchor and set the cable
swage into the notch in the cable anchor.

Suggested initial preload ranges are:

1/4" - Towed vehicle under 2,000 lbs.
1/2" - 2,000 to 3,500 lbs.
3/4" - 3,500 to 5,000 lbs.
1" - Maximum preload

Figure 24

ADJUSTMENT INSTRUCTIONS

The Autostop "Load Ranger" is equipped with a return
spring and an adjusting nut to set the spring pre-load in
proportion to the weight of the towed vehicle. This pre­load will not allow the activation of the towed vehicle's
brakes during light braking of the towing vehicle. This
also prevents application of the towed vehicle's brakes
when descending a moderate grade against engine
compression, jake brake or exhaust brake, but still
allows proportional braking when the towing vehicle's
service brakes are applied. Before making any adjust­ment, drive the rig a few blocks and re-check the
installation for proper cable slack. With a flat blade
screwdriver, rotate the adjusting nut upward with a down
motion of the screwdriver handle to increase the
preload. This will move the nut in the direction of the
towing vehicle, compressing the return spring. Continue
to rotate the adjusting nut to the desired preload. If you
desire the Autostop to activate only during very heavy
braking, adjust to the max. setting. After your

292-2215 7/02 7 of 10

Figure 19

Figure 23

ASSEMBLY INSTRUCTIONS

ASSEMBLY INSTRUCTIONS

1. Slide the cable assembly back into the AutoStop
tube and secure the cable clamp with the round
head screw and hex nut. (Figure 11) Leave
approximately one inch of cable sheathing
extending outside of the AutoStop tube. NOTE: As

described earlier on page 1, your AutoStop can be
configured to give a 2 inch rise. If this is
necessary, the AutoStop tube must be rotated 180
degrees and the cable assembly attached to the
opposite hole. Remember, the cable assembly
MUST protrude out of the lower, driver side of the
AutoStop tube when in use.

2. Lay the AutoStop tube on a table or bench with the
tongue flat side towards you.(Figure 13) Thread the
adjusting nut onto the adjusting bolt half way on the
threads. Slide the compression spring onto the
adjusting bolt all the way onto the adjusting nut.
Then place the end fitting on the other end of spring.
Slide this assembly into the AutoStop tube until
adjusting bolt hole is lined up with the two front
holes of AutoStop tube, then insert the 7/16" hex
bolt through the AutoStop tube and secure bolt with
hex nut. NOTE: If you are configuring the AutoStop

for a 2 inch rise as described on page 1, flip the
AutoStop tube over so the tongue flat side is away
from you before sliding in the shock absorber.

5. Place the pulley divider on the pulley. (Figure 15)

NOTE: The pulley divider is NOT square. It is
slightly wider one direction than the other. During

use, the pulley divider must be oriented long side
vertical, to keep the cable from jumping between
pulleys.

Figure 14

Figure 15

3. Place one of the two identical pulleys with the
beveled edge on the table. Place the long bushing
through this pulley, next place the center spacer
with the chamfer on the bottom right side. Place on
top of the spacer the other pulley with the beveled
edge on top.

4. Set the AutoStop tube aside and find the narrow
pulley. Please note that the narrow pulley's groove
is off center. Set the pulley on the bench with the
groove oriented closest to the bench. (Figure 14)
Insert the short bushing into the pulley and the 5/8
rod into the bushing. (Figure 14)

Figure 16

Figure 17

Figure 13

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DISASSEMBLY / ASSEMBLY INSTRUCTIONS

MAINTENANCE

The AutoStop and the inside of the receiver tube

should be cleaned and lubricated with silicon spray at
1,000 mile intervals to prevent the buildup of road dust
preventing the action to slide with ease. The AutoStop
should be disassembled, thoroughly cleaned and
lubricated every 10,000 miles. At this time the
actuating cable should be replaced if there are any
signs of cable wear. Pages 5 - 9 show actuator cable
routing and parts assembly of the AutoStop.

DISASSEMBLY INSTRUCTIONS

If your AutoStop becomes sluggish or you are in
need of replacing a broken part, the following
disassembly instructions will step you through how to
dismantle, clean and reassemble your AutoStop.

1. Remove the AutoStop from the receiver hitch.
Remove the hex bolt. (Figure 10)

2. Loosen the set screw in the cable anchor and
remove the 5/8 rod going through the AutoStop
tube. NOTE: You may need to tap out the 5/8 rod

with a punch.

3. At this point, slide the pulleys and adjusting bolt
assembly out of the AutoStop tube. NOTE: Use

caution when removing the pulleys. The cable is
coiled around the pulleys several times and may

Figure 10

unwind when removed from of tube. This is normal,
reassembly will be explained in a later section.

4. Remove the round head screw holding the cable
clamp, then pull the cable assembly out of the
AutoStop tube.

5. Clean all parts with a mild solvent such as WD-40
and be sure to dry all parts thoroughly. Use a
brush to insure the inside of the AutoStop tube is
clean as well.

Figure 11

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INSTALLATION / MAINTENANCE

We also include in the kit a lighted switch that should
be installed in the dash of the towing vehicle and will
light up when the brake pedal in the towed vehicle is
pulled on by the AutoStop. If the operator is distracted
by the light, the switch can be turned off. (Figure 9)

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 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, you may want to
splice wire onto the wires you cut to give yourself
working room. The black wire and butt connectors
supplied can be used for this.

3. Strip one end of the yellow wire and twist it together
with the wire coming from the brake pedal 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 or another convenient place,
locate a power wire that is "hot" only when the
ignition switch is on. Cut a piece of black wire to
reach from the "hot" wire to the relay. Use a butt
connector to splice into the "hot" wire and crimp a
spade terminal on the other end and slide it over the
remaining terminal on the relay labeled "86".

7. Route the yellow wire from the relay through the
engine compartment of the car, along the bottom of
the coach and into the dash of the coach. You will
need to provide a disconnect between the car and
the coach if you don’t have any extra terminals in
the plug you are currently using between the coach
and the car. Tie the wire to the frame of the coach
with cable ties or other suitable means.

8. Locate a suitable place in the dash for the switch.
With the switch mounted, cut the yellow wire to
length, strip and crimp on a female spade terminal,
and plug the spade into the switch on the terminal
marked “3”.

9. Locate a bolt to use as a ground. Cut a piece of
the black wire long enough to reach from the switch
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 switch labeled “2”.
NOTE: The terminal marked “1” will not be used.

10. Gather up the wires and the relay. Anchor them up
out of the way so they will not interfere with driving
the vehicle.

Figure 9

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INSTALLATION

When installed properly, the nylon thumb nut
should be showing on top of the carpet. Avoid
abrupt bends in the cable housing as this will cause
friction and premature wear of the cable. If the
cable housing runs through the bumper or the
bumper skirt, drill a 5/16 inch hole there to align the
cable as previously mentioned with the actuating
cable. The cable housing should protrude a 1/2
inch beyond the bumper, or bumper skirt or where
ever the flag terminal is mounted, pointing directly
at the hitch ball. Retract the cable and cut off any
excess cable housing with side cutters. Fig.25

Figure 25

8. Lubricate the cable with silicon spray and feed the
cable back through the cable housing, and secure
the loop around the brake pedal arm allowing the
cable to feed directly and straight into the cable
housing. Use wire ties or wrap with electrical tape

Figure 8

to insure that the loop around the pedal arm does
not loosen when the brake pedal is being used. If
alignment is proper, the cable will feed into the
cable housing when the brake pedal is depressed.

Figure 22

9. Attach the cable thimble into the clevis on the
AutoStop actuating cable with the quick release
pin. (Figure 3 or 4) Run the loose end of the pedal
cable through the clevis and thimble and secure this
loop with the two cable clamps. Place the first
clamp as close as possible to the thimble and the
second cable clamp about four (4) inches from the
first. Before tightening the clamps adjust the cable
length so there is about four to five (4-5) inches of
vertical play in the cable before the towed vehicle’s
braking lights come on. (Fig. 22) Cut off and
discard any excess cable. Recheck this
adjustment after a short trial run. If the towed
vehicle’s brake lights come on at the slightest touch
of the cable, with the cable properly adjusted, the
brake lights are coming on during pedal free travel.
Most brake light switches are not adjustable, so
install a bungee cord from the pedal to the driver’s
seat base to reduce the free travel movement of the
pedal while towing.

10. Install all other safety and towing equipment as
required. The AutoStop only actuates the towed
vehicles brakes. It does not eliminate the necessity
of safety chains, towing lights, transmission pumps
or driveshaft disconnects.

MECHANICAL INSTALLATION NOTES

In Steps 4 and 7 when routing the housing, do not make
a turn tighter than a four (4) inch radius. If you need to
make a bend in the housing you will need to anchor the
housing in the middle of the bend. There are plastic
cable ties and two clamps and stove bolts included with
the kit. You will also need to anchor the housing as
close as possible to the end that sticks out of the grill of
the car. After you have the housing installed and the
cable inserted, lay under the vehicle and have someone
pull on the cable. When pressure is applied to the
cable the housing will tend to try to “straighten out”
through the bends. If there are several places where
this happens, most of the cable pull will be used up
straightening the housing rather than pulling on the
brake pedal. Note where the housing is trying to
straighten and anchor these areas.

ELECTRICAL INSTALLATION

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
AutoStop. To keep this from happening we have
included electrical parts with the kit to automatically
disconnect the 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.

292-2215 7/02 3 of 10

INSTALLATION

a. If readjustment of cable is needed, this is
usually an indication that the cable is too
tight or is hanging up on one of the towing
components.

MECHANICAL INSTALLATION

Figure 6

1. Insert the AutoStop into the receiver tube with the

actuating cable on the drivers side of the
opening. (Figure 6) Align the holes and insert the

cross pin and safety clip (or locking pin). If the
receiver tube is open at the front, it must be closed
to keep road dust out of the mechanism. Clean the
area and cover with tape.

arms are locked in the towing position.

4. Now you are ready to install the brake pedal cable
on the towed vehicle. This cable should run from
the end of the AutoStop actuating cable in a line
about parallel to the bottom plane of the tow bar
coupler, but staying inboard of the driver’s side arm,
probably through the bumper or bumper skirt and up
to the brake pedal through the floor board. Visually
select a route that will not interfere with any moving
components or possibly contact electrical
terminals. Also, make sure cable doesn't come
into contact with any aluminum components, such
as a transmission housing, which could cause
significant wear. Make sure cable route will lead to
the general area where the steering column goes
through the floor.

5. From the drivers seat note the distance and
direction from the steering column to the brake
pedal when the brake pedal is fully depressed. This
will normally be a little below and a little inboard of
the steering column. Mark the spot on the carpet
with chalk where the cable should pass through the
floor after making a loop around the brake pedal
arm. (Figure 7) Measure the distance and direction
and confirm that a drilled hole will not interfere with

2. For coupler style tow bars install a hitch ball of
the matching size for the tow bar coupler, preferably
using a one inch diameter shank and a one inch nut
and lock washer. Do not use a hitch ball that has a
bolt which threads into the ball. For added safety,
it is recommended that after tightening the hitch ball
nut to the required torque, drill the hitch ball nut and
install a cotter key. Note: Be sure tow bar and

Autostop are both parrallel with the ground.

3. Hook up the towed vehicle to the towing vehicle and
gently back the towed vehicle until all the slack is
out of the AutoStop, moving it to its fully extended
towing position. If a self aligning tow bar is

being used, be sure both arms, are fully
extended to the locked towing position. Drive
the towing vehicle forward a few feet if
necessary and pull on the AutoStop actuating
cable to remove all slack. It is very important

that the connecting cables have 4 inches of vertical
slack when in the towing position. This assures the
Autostop will not be active when towing and allows
for turns in either direction. This does not reduce
the effectiveness of the Autostop.

Before the adjustment is made:

(1) Be sure the Autostop is fully retracted to the
towing position. (2) Be sure the cross pin is
inserted through the pulley hole. (3) Be sure both
tow bar arms are fully extended. (4) Be sure both

Figure 7

anything as stated in Step 4. When selecting the
location for the hole, it should be positioned so the
cable is pulling straight away on the brake pedal
arm, not to either side and not up or down. (Figure

7)

6. After you have confirmed that the location for the
hole will not cause any problems, pull the carpet
back and drill a 1/8 inch pilot hole. Allow the drill
bit to just barely break through the metal floor.
Next, inspect where the hole actually is from the
engine compartment side to verify that this location
will not cause problems and to see how the cable
aligns with the brake arm. If the hole needs to be
relocated slightly, redrill and seal the previous hole
with a rivet or sealant.

7. When alignment is correct, enlarge the pilot hole
with a 5/16 inch bit. Cut a slit in the carpet to
correspond to the hole in the floor. Feed the cable
housing through the carpet and hole in the floor
following your selected route as mentioned above.

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REQUIREMENTS

REQUIREMENTS FOR PROPER OPERATION

A. You must have a two (2) inch square receiver type

hitch on your towing vehicle that aligns within two
(2) inches of the height of the tow bar.

NOTE: The tow bar may slope upward toward the
towing vehicle, but should not slope downward
toward the towing vehicle.

The AutoStop needs a level push on the ball
mount tube to operate properly. This requires that
the height of the
receiver tube be
adjusted rather than the
height of the ball as
happens normally.
There are several
options available if you
need to adjust the
receiver tube height.
A two (2) inch drop can
be achieved by welding
another receiver tube
under the existing
receiver tube. (Figure 1)
A six (6) inch drop
receiver is available that
pins into the existing
receiver. (Figure 2)

Figure 1

Figure 2

Combining the drop receiver and a rise in the
AutoStop will give a four (4) inch drop. (Figure 5)

Figure 5

B. You may use any conventional style tow bar with

the hitch ball at the towing vehicle. (No reversed
tow bars).

C. You must tow the vehicle with all four (4) wheels on

the ground.

D. The loaded weight of the towed vehicle must not

exceed the weight rating of any of the towing
accessory components such as; the tow bar, the
hitch ball, the receiver hitch, the receiver cross pin,
the safety chains, or the AutoStop.

NOTE: The AutoStop does not allow you to tow
more than the ratings of your towing hardware, it
just reduces the stopping distance of the
combination.

Figure 3

Figure 4

The AutoStop shown in Figure 3 is set up as it
comes from the factory.

The AutoStop can be reconfigured to give a three (3)
inch rise as shown in Figure 4.

NOTE: If this configuration is used, the internal parts

will need to be rotated so that the actuator cable
still protrudes from the lower driver’s corner of the
AutoStop. See Disassembly / Assembly
instructions Page 5-8.

ILLUMINATED DASH INDICATOR LIGHT IN RV

WARNING: Motorhome dash light must be installed

according to installation instructions or warranty
will be void.

A. RV DASH LIGHT

1. Dash light will allow a visual indication that the
towed vehicles' brakes are activated.

2. Should light remain "ON" after braking,
corrective action must be taken. "STOP" the RV to
investigate. You may be experiencing a
malfunction of the system, which would require you
to check, the braking system for proper operation.

a. Cable tension should comply with the
installation instructions.

b. Check wiring of relay in towed vehicle to
insure proper installation.

c. If breakaway device is installed, refer to its
installation instructions.

3. Should dash light activate while turning,
corrective action must be taken. "STOP" the RV to
investigate.

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