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BrakeMaster 9100
Installation Instructions Manual
24 pgs1.72 Mb0
Owner's Manual
18 pgs5.61 Mb0

Roadmaster BrakeMaster 9100, BrakeMaster 9160 Installation Instructions Manual

BrakeMaster 9100 and 9160
for motorhomes with air or air over hydraulic brakes
Installation Instructions
ROADMASTER, Inc. • 6110 NE 127th Ave. • Vancouver, WA 98682 • 800-669-9690 • fax 360-735-9300 • roadmasterinc.com
Towing and Suspension Solutions
WELCOME TO THE ROADMASTER FAMILY!
hese instructions have been prepared to acquaint you with the installation of your BrakeMaster, and to
T
TABLE OF CONTENTS
Safety definitions ..............................inside front cover
Before you begin the installation
(installer’s checklist) .............................................. 1
Air cylinder assembly and
compression fitting parts ....................................... 2
Install the air cylinder anchor plate ........................ 3-5
Install the break away system ................................ 6-7
Install air lines in the towed vehicle .......................8-9
Install the motorhome monitor system ................ 10-11
Install the motorhome air line ............................. 12-13
System test ......................................................... 14-15
Brake light solutions ................................................ 16
Ford ‘neutral tow’ vehicles .................................. 17-18
Troubleshooting ....................................................... 19
Vehicle-specific components .................................... 20
Index ........................................................................ 21
IMPORTANT NOTICE!
Safety Definitions
Statements in these instructions identified as follows are of special significance:
WARNING indicates a potentially hazardous situ­ation which, if not avoided, could result in property damage, serious personal injury, or even death.
Red type is used to emphasize warnings of par­ticular significance.
CAUTION indicates a potentially hazardous situ­ation which, if not avoided, may result in property damage, or minor or moderate personal injury.
Red type is used to emphasize cautions of par­ticular significance.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
Red type is used to emphasize cautions of par­ticular significance.
NOTE Refers to important information and is placed in italic type. It is recommended that you take special notice of these items.
BEFORE YOU BEGIN THE INSTALLATION…
fore it can be towed — verify that removing the fuse(s)
will not disrupt power to BrakeMaster, or otherwise af-
These instructions pertain to the initial installa­tion only. Operating instructions are contained in the owner’s manual. Read all 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.
1. ALWAYS CHECK THE ROADMASTER WEBSITE —
www.roadmasterinc.com — for vehicle-specific informa­tion. Select ‘Vehicle-Specific Info,’ enter the motorhome and towed vehicle make, model and year, then select ‘Braking Systems’ and scroll down the page.
2. If the battery must be disconnected for towing,
a stop light switch must be installed. ROADMASTER manufactures stop light switch kits for a number of ve­hicles; to see if one is available for any specific vehicle, visit www.roadmasterinc.com and select ‘Vehicle-Spe­cific Info,' enter the vehicle make, model and year, then select ‘Braking Systems' and scroll down the page.
Note: if a stop light switch kit is listed on the website for any particular vehicle, it is required. Note: an Automatic Battery Disconnect (part number
765) is available for vehicles which must be towed with the battery disconnected. If you choose to install the Automatic Battery Disconnect, a stop light switch is still required; the Brake-Lite Relay is not required.
3. If the vehicle to be towed has an ‘active’ (or, ‘continuous power assist’) braking system, or if the vehicle is not equipped with power brakes — order
the optional Brake Pressure Reducer (part number
900002) to adapt the vehicle to the BrakeMaster sys­tem. Vehicles with ‘active’ brake systems include several hybrid vehicles, such as some models of the Ford Es­cape hybrid and the Mercury Mariner hybrid, as well as the H3 Hummer. These vehicles, and others with these systems, are designed so that even when the vehicle is set to ‘tow’ mode, the braking system is still active, thus requiring minimal pressure to engage the brakes.
If the vehicle to be towed has an ‘active’ brak­ing system, or if the vehicle is not equipped with power brakes, install the optional Brake Pressure Reducer. If the reducer is not installed, BrakeMaster will apply excessive force to the towed vehicle’s brake pedal, causing severe tire and/or brake system dam­age, as well as other, consequential damage.
fect the installation or operation.
5. Optional seat adaptor brackets are required for some towed vehicles and simplify the installation for
others. Determine if a seat adaptor bracket is required, or if one is available, for the towed vehicle — visit www.roadmasterinc.com and select ‘Vehicle-Specific Info,' enter the vehicle make, model and year, then select ‘Braking Systems' and scroll down the page.
6. Test-fit the brake pedal clamp — although the pedal clamp fits the vast majority of vehicles, in rare circumstances, it may require additional adjustment. If the pedal clamp does not attach to the brake pedal as described on page 3, call the ROADMASTER Technical Service Department at 800-669-9690.
7. Check the towed vehicle’s brake lights — Brake- Master must function when all adjustments have been made to prepare the vehicle for towing. These adjust­ments may include: turning the ignition key to the “tow” position; pulling fuses; disconnecting the battery; and setting the transmission to a particular gear or in a particular sequence. However, some vehicles’ brake lights will not operate when these adjustments have been made. Check to see if this is the case: after all adjustments have been made, apply the brakes, and check to see if the brake lights illuminate. If the brake lights do not illuminate, a two-prong stop light switch and 10-amp fuse must be installed. ROADMASTER manufactures stop light switch kits for a number of vehicles; to see if one is available for any specific vehicle, visit www.roadmasterinc.com.
Note: check the owner’s manual to see if the vehicle is equipped with an “automatic shut down” feature. If this is the case, ensure that the vehicle is not in auto­matic shut down mode before performing this test. Note: if you must install a Brake-Lite Relay — see step 8, below — a stop light switch is not required.
8. An optional Brake-Lite Relay may be required.
Refer to “Brake light solutions” for instructions on how to determine if the relay must be installed.
Note: a stop light switch (see steps 2 and 7 above) and a Brake-Lite Relay are mutually exclusive — if you use one, the other is not necessary.
9. An optional tee may be required to connect the BrakeMaster air line to the motorhome brake relay valve or air booster housing. Refer to “Install the motorhome air line.” These tees are available in two sizes: ½" (part num­ber 450076) and 3/8" (part number 450077).
10. If the motorhome is equipped with air over hy­draulic brakes — an additional amount of air line (part
number 450700) may be required.
4. If fuse(s) must be removed from the vehicle be-
1
2
INSTALL THE AIR CYLINDER ANCHOR PLATE
To determine where the anchor plate will be installed, first attach the pedal clamp to the brake pedal. Follow steps one through six below…
1. At the towed vehicle, slide the driver’s seat back, as far as it will go.
2. Verify that the pedal clamp is right side up, as shown in Figure 1 — the arrow on the sticker will point “Up” when the pedal clamp is properly positioned.
3. Pull the hairpin clip (Figure 1) out, then lift the slot- ted arm (Figure 1) up and out of the way.
4. Move the pedal clamp over the brake pedal. Then, hold the clevis (Figure 2) and pull back on the spring post (Figure 2), until the tabs under the pedal clamp are wide enough to clear the brake pedal.
5. Fit the pedal clamp onto the brake pedal, so that all four tabs are hooked around it (Figure 3). Then, release the spring post.
Note: on the initial installation, it may be necessary to adjust the tabs on the pedal clamp — use pliers to bend any or all of the tabs so that they hook around and under the towed vehicle’s brake pedal.
Once the tabs have been adjusted to a specific brake pedal, no further adjustment to the pedal clamp is necessary for that vehicle.
If BrakeMaster is switched between towed vehicles, always check the pedal clamp on the initial installation. Verify that all four tabs are hooked around and under the brake pedal. If necessary, bend the tabs to fit, as described above.
Figure 2
Figure 1
Make certain that all four tabs on the pedal clamp are securely hooked around the brake pedal (Figure
3). If the tabs are loose when the vehicle is towed, the pedal clamp can rotate out of position and hold the brake pedal down, even when BrakeMaster is not activated, which will cause tire and/or brake damage, or other consequential, non-warranty dam­age.
6. Swing the slotted arm back over the spring post, fit the spring post through one of the slots, and reattach the hairpin clip (Figure 3).
7. Now that the pedal clamp is in place, attach the anchor plate (Figure 4) —
Note: optional seat adaptor brackets are required for some towed vehicles and simplify the installation for others. Before attaching the anchor plate, de­termine if a seat adaptor bracket is required — visit www.roadmasterinc.com. Select ‘Vehicle-specific Info,' enter the vehicle make, model and year, then select ‘Braking Systems’ and scroll down the page.
Choose a mounting point under the driver’s seat as
Figure 3
far back as possible — ideally, the anchor plate should be concealed when the driver's seat is moved forward, and visible only when the driver's seat has been moved back as far as it will go.
BrakeMaster is shipped with the air cylinder at the shortest position. If necessary, lengthen the reach of the air cylinder, to position the anchor plate at the point you have chosen — remove the two bolts and nylon nuts
continued on next page
3
INSTALL THE AIR CYLINDER ANCHOR PLATE
continued from preceding page
(Figure 4) attaching the cylinder to the adjustable arm (Figure 4). Slide the air cylinder (Figure 4) up the ad­justable arm until the anchor plate is over the point you have chosen. Replace the two bolts and nylon nuts.
Note: if BrakeMaster is switched between towed vehicles, it may be necessary to lengthen or shorten the reach of the air cylinder, as described above.
Note: if the vehicle is equipped with an automatic pedal positioning system, adjust the brake pedal to its farthest extension (as close as possible to the driver’s seat) before positioning the air cylinder and the mount­ing post. This will eliminate the possibility of positioning the anchor plate too close to the brake pedal.
8. Next, if necessary, move the air cylinder to the left or the right, until the mounting post (Figure 4) is directly in line with the brake pedal.
The air cylinder must be mounted directly in line with the brake pedal. If it is mounted at an angle to the brake pedal (to one side or the other), the air cylinder may jam in the extended position when BrakeMaster is activated, which will cause severe brake system damage, as well as other consequen­tial, non-warranty damage.
Note: the anchor plate can be rotated clockwise or counterclockwise, if necessary, to clear any obstructions — to rotate the anchor plate, remove the air cylinder and lock the plate in a vise. Use a half-inch open-end wrench to loosen the mounting post, while holding the retaining screw (at the bottom of the plate) with an Allen wrench. Do not turn the retaining screw with the Allen wrench, as you may damage the wrench or the screw. When the mounting post is loose, rotate the anchor plate. Then, tighten the mounting post.
9. Before attaching the anchor plate, verify that the
Figure 4
following conditions are met:
A. Make certain that the pedal clamp is not de- pressing the towed vehicle’s brake pedal — examine the brake pedal, and also check the towed vehicle’s brake lights, to make certain they are not illuminated.
Make certain that the pedal clamp is not depress-
ing the towed vehicle’s brake pedal. If the pedal clamp is pushing the brake pedal down, the brakes will be applied continuously when BrakeMaster is connected, which will cause severe tire and/or brake system damage, as well as other consequential, non-warranty damage. Failure to follow these instructions may cause property damage, personal injury or even death.
B. When it is connected, the air cylinder must be pulled back toward the anchor plate in order to insert the safety pin (Figure 4) through the mounting post.
The air cylinder must be pulled back when it is connected, in order to create sufficient spring ten­sion to keep the weight of the cylinder off the brake pedal. If the cylinder is not pulled back when it is connected, the weight of the cylinder may cause the pedal clamp to depress the towed vehicle’s brakes continuously, which will cause excessive brake wear, brake system damage, or other conse­quential, non-warranty damage.
C. The pedal clamp must be flat against the brake pedal and properly secured with the hairpin clip (Figure
3).
D. Make certain that there is sufficient clearance between the mounting post and the bottom of the seat to allow the seat to slide properly.
10. Once the four conditions in step 9 (above) are met, attach the anchor plate. (It may be helpful to remove the driver’s seat to facilitate the rest of the installation.)
The anchor plate can be attached on top of the carpet, or underneath it.
A. To mount the plate on top of the carpet, first use the anchor plate as a template and mark the five holes to be drilled.
Before drilling, make certain that the retaining screw (at the bottom of the mounting post) is fully tightened. (To tighten the screw, reverse the instructions in step 8, above.) Also, make certain that you will not drill through any wiring or electrical components underneath the carpeting, or damage any components on the other
continued on next page
4
INSTALL THE AIR CYLINDER ANCHOR PLATE
continued from preceding page
side of the floorboard.
Do not drill through any wiring. The air bag sen­sor wire may be located under the driver’s seat. Drilling into this wire may disable the air bag sys­tem, or may cause the air bags to deploy immedi­ately, which may cause severe personal injury. Failure to follow these instructions may cause property damage, personal injury or even death.
Next, drill five ¼" holes at the points you marked. Drill through the carpet and the floorboard. Use caution to prevent the drill bit from catching on threads in the carpet and unraveling it.
B. If mounting the anchor plate underneath the carpet, cut a small flap in the carpet to allow the mount-
ing post to protrude through it.
As described above, use the anchor plate as a tem­plate, and drill five ¼" holes through the floorboard.
Figure 5
STANDARD
INSTALLATION
DRILL 1/4" HOLE
11. Next, attach the anchor plate as shown in Figure 5, using the provided ¼" x 1" hex head bolts and self­locking flange nuts.
12. If you find that tightening the flange nut on a bolt is difficult due to a tube, channel or other obstruction under the floorboard, use one of the provided jack nuts to attach the bolt. Refer to Figure 6.
Note: if one or more jack nuts are used, the anchor plate cannot be mounted on top of the carpet.
To attach a bolt with a jack nut, drill a ½" hole through the floorboard at the point you marked in step
10.
Note: do not drill out the hole in the anchor plate.
Next, insert the jack nut into the hole (See Figure
6) and bolt through the anchor plate, using one of the ¼" x 1" hex head bolts.
13. This completes the anchor plate installation. You can leave the air cylinder assembly in place — it must be attached to install an air line fitting in a later step — or you can remove it, if it interferes with the installation.
Automatic pedal positioning systems may affect the towed vehicle braking system. Determine if the vehicle to be towed is equipped with pedal presets. Proper connection of the brak­ing system may be affected by these presets; if the vehicle is so equipped, note the original installed position and return to that position before towing the vehicle. If the brake pedal is not at the original installed position when the vehicle is towed, the pedal clamp may apply excessive braking force, which will dam­age the brake system and/or electrical system, and may cause brake or electrical system failure, as well as other non-warranty damage. Failure to follow these instructions may cause property damage, personal injury or even death.
Figure 6
DRILL 1/2" HOLE
JACK NUT
INSTALLATION
NOTE: DO NOT
DRILL OUT THE
HOLE IN THE AN-
CHOR PLATE!
5
INSTALL THE BREAK AWAY SYSTEM
Note: the BrakeAway™ system is included with the 9160; it is an optional accessory for the 9100.
Step One
Install the air reservoir
1. First, choose a location for the air reservoir (Figure
7). The air reservoir is mounted in the towed vehicle, most often in the engine compartment, but it may be attached anywhere an air line can be routed from the top of the air reservoir to the front of the vehicle, and where the drain valve (Figure 7), at the bottom of the reservoir, is easily accessible.
Choose a location that meets the following condi­tions:
• An air line will be attached to the reservoir in a later step. One end will be routed to the driver’s side of the passenger compartment; the other end will be routed to the front of the vehicle. This air line cannot be closer than two feet from any heat source, such as the engine or exhaust system, which might damage the air line.
• The air reservoir must be mounted away from any moving parts, so that the air reservoir will not be dam­aged by, or interfere with, the proper operation of any components.
• Choose a location that will allow the bottom of the air reservoir to be mounted lower than the top, so that any accumulated water can be drained from the tank. The reservoir cylinder does not have to be perfectly straight up and down, but the drain valve must be the lowest part of the reservoir.
• The reservoir will be attached with two of the sup- plied ¼" x 1" hex bolts and nuts. Choose a location that will allow you sufficient access to tighten the hex nuts from the other side.
Note: because the air reservoir will be charged with compressed air, it cannot be mounted inside the pas-
senger compartment of the vehicle.
2. Once you have chosen a location for the air res- ervoir, fold the two rubber clamps (Figure 7) over the cylinder. Press the ends of each clamp together, until the pre-drilled holes align.
Test-fit the reservoir and slide the clamps up or down the cylinder, if necessary, until the pre-drilled holes are both over a surface where the hex bolts and nuts will hold each clamp in place. Mark the center of each hole for drilling, and set the reservoir aside.
Before drilling, make certain you will not damage any components on the other side. Then, drill a ¼" hole through the two points you have marked.
Before attaching the clamps, rotate the top of the reservoir so that the two wires at the solenoid valve (Figure 10), as well as the two brass air compression fittings (Figure 10), will be easily accessible.
Position the reservoir and clamps over the two holes, and secure the reservoir in place with one of the ¼" x 1" hex bolts and nuts at each clamp.
Step Two
Mount the break away switch
1. Mount the break away switch (Figure 7) at the front
of the vehicle, on the driver’s side. Choose an area you can easily reach, with a surface of sufficient strength to hold the switch firmly in place, so that the break away pin (Figure 7) will pull freely from the switch. Mount the switch in a horizontal position, with the break away pin facing toward the motorhome.
Ensure that the break away pin can be pulled free­ly away from the towed vehicle, without any obstruc­tions.
Figure 7
6
Do not attach the break away switch to the tow bar or the tow bar bracket. If the tow bar or bracket fails, the break away switch will separate with it, preventing the break away system from activating. If the towed vehicle separates, the brakes will not be applied, which may cause property damage, per­sonal injury or even death.
Step Three
Connect the wiring
Note: if the vehicle’s battery must be disconnected for towing and an automatic battery disconnect has been installed, additional modifications are necessary. If a ROADMASTER Dinghy Battery Manager (part number
continued on next page
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