Roadmaster BrakeMaster 9000, BrakeMaster 9060, 98300 Installation Instructions Manual
BrakeMaster 9000 and 9060
Second Motorhome Kit
part number 98300
Installation Instructions
ROADMASTER, Inc. • 6110 N.E. 127th Ave. • Vancouver, WA 98682
800-669-9690 • Fax 360-735-9300 • roadmasterinc.com
853811-04 12.17 © 2007-2017 ROADMASTER, Inc. All rights reserved.
Time Tested • Time Proven
Welcome to the ROADMASTER family!
hese instructions have been prepared to acquaint you with the installation of your BrakeMaster second
T
motorhome kit, and to provide you with important safety information.
Read these instructions, as well as the owner’s manual and all accompanying literature, completely. Understand
how to install and operate your BrakeMaster and carefully follow the instructions and safety precautions.
Your BrakeMaster second motorhome kit has a one-year limited warranty. To qualify for your warranty, fill out
and return the enclosed product registration card within 30 days of purchase.
We thank you for your patronage and greatly appreciate your discerning taste.
Table of Contents
Wiring diagrams ................................inside front cover
Safety definitions ....................................................... 1
Before you begin the installation
(installer’s checklist) .............................................. 2
Wire the air compressor ......................................... 2-4
Install the proportioning valve ................................. 5-8
Bleed the brakes .................................................. 9-11
Wire the proportioning valve .................................... 12
Install the air lines ................................................... 13
Install the motorhome monitor system ..................... 14
Final connections and system test ..................... 15-16
Troubleshooting .................................................. 17-18
IMPORTANT NOTICE!
Safety Definitions
These instructions contain information that is very important to know and understand. This information is
provided for safety and to prevent equipment problems. To help recognize this information, observe the following
symbols:
CAUTION
WARNING indicates a potentially hazardous situ-
ation which, if not avoided, could result in property
damage, serious personal injury, or even death.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in property
damage, or minor or moderate personal injury.
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
NOTE
Refers to important information and is placed in italic
type. It is recommended that you take special notice of
these items.
All illustrations and specifications contained herein are based on the latest
information available at the time of publication. ROADMASTER, Inc. reserves
the right to make changes, at any time, without notice, in material, specifications and models, or to discontinue models.
1
Before you begin the installation…
1. Check online at the ROADMASTER web site —
www.roadmasterinc.com — for vehicle-specific information. Select ‘Vehicle-Specific Info,’ then ‘Supplemental
Braking Systems.’ Enter the vehicle make, model and
year, then scroll down the page.
2. If the motorhome brake line has metric fittings it
will be necessary to use a metric-to-standard T-fitting
to attach the proportioning valve. This fitting is not
supplied in the kit.
Identify the size of the metric brake line before
the installation. If it is 10 or 12 millimeters, contact
ROADMASTER — T-fittings in both sizes are available.
The 10 millimeter T-fitting (part number 7923) fits
virtually all metric brake lines for this application; the
part number for the 12 millimeter fitting is 7921.
In the unlikely event that the brake line is not 10
or 12 millimeters, we recommend you contact a local
hose and fitting shop or other contractor and arrange to
have the brake line cut and flared so that the standard
brake line tees supplied in the kit can be installed.
3. If the motorhome has a one-piece brake line (i.e.,
there are no brake line unions), or if the brake line
unions are difficult to access, a short length of steel
brake line will be necessary to connect the proportioning valve. (See “Install the Proportioning Valve.”) This
section of steel brake line is not supplied; contact an
auto parts store.
These instructions pertain to the initial installa-
tion of the second motorhome kit only. Installation
instructions for the complete BrakeMaster system
(including instructions for all components in the
towed vehicle) are contained in the original installation instructions.
Operating instructions for the BrakeMaster system are contained in the owner’s manual.
For the most recent versions of the instructions
and manual, visit www.roadmasterinc.com.
Read the appropriate instructions before installing or operating the BrakeMaster system. Failure to
understand how to install or operate BrakeMaster
could result in property damage, personal injury or
even death.
Wire the air compressor
1. Before wiring the air compressor (Figure 1), first
choose a mounting location — the air compressor assembly must be installed in a clean, dry area (ideally, a
storage compartment), within 20 feet of the motorhome
starting battery.
The compressor is attached with four screws — one
at each corner of the air compressor housing. The surface and underlying material at these four points must
provide sufficient support to hold the compressor firmly
in place.
The compressor may be mounted horizontally or
vertically; however, it must be mounted so that the
drain valve (Figure 1) is pointing down. Condensation
in the air tank must be drained periodically, through this
valve. A short length of rubber hose is included for this
purpose — the hose can be attached to the valve and
routed to the exterior of the motorhome. If possible,
continued on next page
Figure 1
2
Wire the air compressor
continued from preceding page
choose a mounting location for the compressor where
a ½" hole can be drilled near the drain valve, through
to the exterior of the motorhome.
CAUTION
Do not mount the air compressor…
• in a slide-out, or near moving components — the
wiring and/or the compressor may detach.
• near any heat source such as the engine, exhaust system or muffler — excessive heat will damage the wiring, tubing or other components, which
will cause the compressor to fail.
• where it will be exposed to the elements — if
the air compressor is mounted near the front grille,
for example, it may draw an excessive amount of
dirt, dust or road debris into the air tank and then
into the air lines, which may damage components
connected to the air lines.
Failure to follow these instructions may cause
non-warranty damage to the air compressor, the air
cylinder or other components of the braking system.
2. Position the air compressor at the mounting location you have chosen. Using the four pre-drilled holes
in the housing (one at each corner) as templates, drill
four pilot holes. Before drilling, make certain you will
not damage any components on the other side.
Do not attach the air compressor now — in most
cases, it will be considerably easier to connect the wiring (and, later, the air lines) with the compressor loose.
3. Route the bare end of the bonded pair of black and
red wires from the motorhome starting battery to the
air compressor. (If the motorhome has more than one
starting battery, route the wire from either battery.)
battery may be near capacity. Any additional power
draw may blow the fuse(s) to electrical components
already connected to the auxiliary battery.
Avoid moving parts (slide-outs, sliding generators,
sliding battery trays, etc.), sharp edges or “hot” components, such as the engine or exhaust system, as
you route the wire from the starting battery to the air
compressor. Where appropriate, use one or more of
the included wire ties to secure the wire in place.
4. At the air compressor, cut the bonded pair of black
and red wires to length. Using one of the small ring terminals, attach the red wire to the terminal block screw
opposite the pre-attached red wire (Figure 2.)
Next, use another small ring terminal to attach the
black wire to the terminal block screw opposite the
pre-attached black wires (Figure 2).
Note: due to manufacturing variances, the preat-
tached red and black wires may be mounted to different
terminal block screws than those shown in Figure 2. If
this is the case, match color to color — red wire opposite
red wire, and black wire opposite black wires.
5. At the starting battery, insert the supplied 20-amp
continued on next page
Figure 2
CAUTION
Do not use an auxiliary (“house”) battery as a
power source for the air compressor — the auxiliary
Figure 3
3
Wire the air compressor
continued from preceding page
ATC fuse into one of the provided fuse holders. The
fuse holders are attached to a short length of wire,
with a butt connector at one end and a ring terminal
on the other (Figure 3).
Use the butt connector to attach the short length of
wire with the fuse holder and the 20-amp ATC fuse to
the end of the red wire. (See the electrical schematic
on the inside front cover.)
6. At the starting battery, attach one of the large ring
terminals to the end of the black wire.
The black wire will be connected to the negative
terminal of the starting battery; the red wire will be
connected to the positive terminal. To eliminate the possibility of personal injury or equipment damage, do not
connect the wires until the installation is complete.
The 20-amp fuse must be installed at the positive
terminal. If a short circuit develops and the fuse
is not in place, the battery and other equipment
may be damaged; additionally, sparks may cause
an electrical fire or a battery explosion.
7. Choose the most convenient ignition (switched)
power source from the motorhome — any 12VDC+
source which is powered only when the motorhome’s
ignition is turned on. Route the bare end of the supplied
length of blue wire from this point to the air compressor.
As before, avoid moving parts, sharp edges or “hot”
components such as the engine or exhaust system as
you route the blue wire to the air compressor. Where
appropriate, use wire ties to secure the wire in place.
8. At the air compressor, cut the blue wire to length.
Using one of the small ring terminals, attach the blue
wire to the terminal block screw labeled “blue wire” in
Figure 2.
Note: due to manufacturing variances, the preattached blue wire may be mounted to a different terminal
block screw than the one shown in Figure 2. If this is
the case, match color to color — blue wire opposite blue
wire.
9. Insert the remaining 10-amp ATC fuse into the second provided fuse holder. As in step 5, attach the fuse
holder and ring terminal to the end of the blue wire with
the butt connector (Figure 3).
of personal injury or equipment damage, do not connect
the blue wire until the installation is completed.
CAUTION
In order to prevent damage from a short circuit, the
10-amp fuse must be within six inches of the electrical connection. If the 10-amp fuse is farther than six
inches, a short circuit may cause significant damage
to the towed vehicle’s electrical system, an electrical
fire, or other consequential, non-warranty damage.
The blue wire will be connected to the ignition power
source you chose in step 7. To eliminate the possibility
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