Hopkins BB005 Users Manual
Phone (800) 470-2287
Brakebuddy.com
Dedicated to towing safety
TM
TABLE OF CONTENTS
Congratulations on the purchase of your new BrakeBuddy®! The BrakeBuddy®was designed and built as an
auxiliary braking system to operate in conjunction with the existing braking system in your towed vehicle.
Use of the BrakeBuddy®in a manner inconsistent with these instructions may result in damage to your
vehicle, serious injury or death. You must read and understand these instructions prior to the use of this
product.
If you have any questions after reading these instructions, please call BrakeBuddy®customer service at 1 800-470-2287.
CONTENTS
Break Away Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 2
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
Removal Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
Remove the BrakeBuddy®and components from the shipping carton. The complete system consists of:
Main BrakeBuddy®Unit
Clevis Assembly
Handle and Knob
Remote Alert System
Break-Away System
olt DC Cord
Alert
ransmitter
12 V
Control Panel
Handle
Break-A
(A) 1, 1/16” coiled break-
(B) 1 junction box with wiring
(C) 1 strap clamp
(D) 2 hex socket head
(E) 2 flat washers
(F) 2 lock washers
(G) 2 sheet metal screws
(H) 2 grommets
(I) 5 nylon ties
(J) 1 loose velcro patch
way Contents
away cable with one large
and one small clip on the
ends
harness
capscrews
H
I
E
F
J
A
D
G
Air Cylinder Arm
Clevis
Remote
T
B
C
E
F
D
Main Unit Components
311-0288-062 Rev. C 12/08
© 2008 Hopkins Manufacturing Corporation
Breakaway System Components
Pg. 1
Dedicated to towing safety
BREAK-AWAY INSTALLATION
The Break-Away is an important part of the
BrakeBuddy system and is required by
law in most states. Do not operate
your BrakeBuddy without a properly
functioning Break-Away.
Phone (800) 470-2287
Brakebuddy.com
TM
J
FIG. 2
Installing Junction Box
Find a convenient, sturdy place on the
1.
front of your towed vehicle to mount
the junction box
installed on the driver’s side of the
vehicle if possible.
2. Clean the mounting surface and
attach the velcro patch (J) (Fig. 2).
3. Attach the junction box (B) to the
velcro patch (J) so the pin with the
ring faces forward and the wiring
harness feeds back into the engine
compartment.
4. Place the mounting bracket (C) over
the junction box (B) and mark the
hole locations to be drilled and
tapped.
5. Remove bracket (C) and junction box (B). Drill
marked holes with a1/8" metal drill bit.
NOTE: For thin sheet metal or plastic, it may be
necessary to reinforce the plastic or thin metal to
ensure the bracket will not separate from the
when the break-away pin is pulled. If you are going
to drill through thicker metal, use hex socket head
capscrews (D). You will need to drill a hole using a
#25 drill bit and tap the hole using a 10-24 tap.
(B). This should be
vehicle
B
C
D
G
FIG. 3
FIG. 4
K
6. Replace the junction box (B) and attach the
bracket (C) using hex socket head capscrews
(D) or sheet metal screws (G) provided (Fig. 3).
7. Locate a place in the firewall that will allow the
wiring harness to be fed through into the drivers’
side compartment of the towed vehicle. Use of
an existing hole would be most convenient.
8. If there is no existing hole, drill a 15/32"
diameter hole through the firewall (Fig. 4 /
Be careful not to drill into any functional
components of the vehicle.
9. Starting from the junction box (Fig. 4 / B), route
311-0288-062 Rev. C 12/08
© 2008 Hopkins Manufacturing Corporation
K).
B
M
H
Pg. 2
Dedicated to towing safety
TM
BREAK-AWAY INSTALLATION
Phone (800) 470-2287
Brakebuddy.com
the black electrical wire up to the firewall
keeping it away from hot or moving engine
components. Secure using the nylon ties (I)
provided (Fig. 4 / M).
10. Feed the black wire through the hole in the
firewall and into the passenger compartment
(Fig. 5).
11. Place the split rubber grommet provided (H)
over the black electrical wire (Fig. 6) and
slide it into the 15/32" hole and fasten it into
place (Fig. 7).
NOTE: Failure to properly install the 15/32"
rubber grommet may result in harmful fumes
entering the vehicle, or damage to the wires.
Using the Break-Away System
After attaching your towed vehicle to your coach
and all hook-ups are complete, you will need to
attach the break-away cable (A) from the junction
box (B) to the motorhome. On the motorhome
end attach to a permanent location. The frame
of the vehicle is recommended. DO NOT
attach or wrap the cable around the tow bar,
hitch or bumper.
1. Attach the small clip on the cable (A) to the
loop on the pull pin of the junction box (Fig. 8 /
O), and then attach the large clip to the
motorhome (Fig. 8 / P). The coiled break-
away cable fits all applications and needs no
adjustment.
FIG. 8
FIG. 7
P
FIG. 5
Q
FIG. 6
O
2. Setup the BrakeBuddy in your towed vehicle
and plug the junction box wire harness into
the receptacles on top of the BrakeBuddy
(Fig.
9 / Q).
3. Before the start of every trip, pull the breakaway pin to test that the break-away system
activates the Brake Buddy.
4. When the use of the towed vehicle is needed,
simply unhook the small clip from the loop on
the pull pin of the junction box (B). Unplug the
junction box wire harness from the
BrakeBuddy and coil the wire under the
dashboard or under your floor mat (Fig. 10).
311-0288-062 Rev. C 12/08
© 2008 Hopkins Manufacturing Corporation
FIG. 9
FIG. 10
Pg. 3
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