Roadmasterinc /patents For Patent Info

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roadmasterinc.com/patents for patent info

Welcome to the ROADMASTER family!This manual has been prepared to acquaint you with the installation, operation, care and maintenance of your BrakeMaster, and to provide you with important safety information.Read your owner’s manual cover to cover. Understand how to install and operate your BrakeMaster, and carefully follow the instructions and safety precautions.We thank you for your patronage and greatly appreciate your discerning taste.Table of contentsSafety definitions. inside front coverComponents.1Operation.2-5Prepare the vehicles for towing.2Attach the pedal clamp and air cylinder. 2-4Connect the air line, patch cordand break away system. 4-5Disconnecting the air cylinder.5Test the system.6-7Using the quick couplers.7The motorhome monitor LED.8If the engine must be started periodically.8Maintenance.9Storing your BrakeMaster.9TroubleshootingBrakeMaster 9100 and 9160. 10BrakeMaster 9060. 11-12Partsfor all BrakeMaster systems. 13-14BrakeAway — models 9160 and 9060. 14models 9100 and 9160 only. 14model 9060 only. 15Index. 16All 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.Save this manualSave this manual for future reference. It contains important sections relative to safety, use, maintenance, partsreplacement and other information. Therefore, make surethis manual is always with you when you’re towing. Youmay download or print a copy of the most current manualat www.roadmasterinc.com (under ‘Support').This manual contains operating instructions only. Installation instructionsare in a separate document.Read all instructions before installingor operating the BrakeMaster system. Failure to understand how to install or operate BrakeMaster could result in property damage, personal injuryor even death.The BrakeMaster serial number is on a label on theair cylinder (right). You willneed this number whenyou fill out your productregistration card.Write down the serial number in the space below, so that it will be availablefor future reference Serial number:IMPORTANT NOTICE!Safety DefinitionsThis manual contains information that is very important to know and understand. This information is provided forsafety and to prevent equipment problems. To help recognize this information, observe the following symbols:CAUTIONWARNING indicates a potentially hazardous situation which, if not avoided, could result in propertydamage, serious personal injury or even death.CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if notavoided, may result in property damage.CAUTION indicates a potentially hazardous situation which, if not avoided, may result in propertydamage or minor or moderate personal injury.NOTERefers to important information and is placed in italictype. It is recommended that you take special notice ofthese items.

ComponentsThis overview is intended to introduce you to the major components in the BrakeMaster system and to briefly explain theirfunctions. While some of these components will be “out of sight and out of mind,” you will connect and disconnect othersevery time you tow. Subsequent sections will explain how to operate and maintain your BrakeMaster system in full detail; acomplete parts list is also included.15The motorhome monitor light will illuminateevery time BrakeMaster applies the towedvehicle’s brakes.The patch cord connects the motorhomemonitor system, as well as the supply of compressed air, between the two vehicles.26The air compressor(model 9060 only) supplies compressed air to the proportioning valve.3When the motorhome brakes are applied,the proportioning valve (model 9060 only)measures the hydraulic brake pressure anddelivers a proportional amount of compressedair to the air cylinder.4Quick connects allow you to easily connectand disconnect the supply of compressed airfrom the two vehicles and from the air cylinder.The air cylinder uses air pressure from themotorhome to depress the towed vehicle’sbrake pedal.You will connect the air cylinder before towing and disconnect it when you reach yourdestination.7The BrakeAway system will bring yourtowed vehicle to a controlled stop in the unlikely event of a break away.You will connect the break away cable between the two vehicles before towing and disconnect it when you reach your destination.1

OperationCAUTIONThe Brake Pressure Reducer (part number 900002)is required for: 1) all towed vehicles with full-time (‘active’) power braking systems; and 2) all towed vehicleswithout power brakes —1) Vehicles with ‘active’ brake systems include several hybrid vehicles, such as some models of the FordEscape hybrid and the Mercury Mariner hybrid, as wellas the H3 Hummer. These vehicles, and others withthese systems, are designed so that even when thevehicle is set to ‘tow’ mode, the braking system is stillactive, thus requiring minimal pressure to engage thebrakes.2) BrakeMaster is designed to work with vehiclesthat have a power brake system (even though thepower brakes are not activated while towing).If the Brake Pressure Reducer is not installed invehicles with ‘active’ braking systems or in vehiclesthat do not have power brakes, BrakeMaster will applyexcessive force to the towed vehicle’s brake pedal,causing severe tire and/or brake system damage, and/or other consequential, non-warranty damage.Step A2. Make certain that the towed vehicle’s emergency brakeis released.Failure to release the towed vehicle’s emergencybrake before towing will result in severe brake damage, or a brake system fire. Damage caused by neglecting to release the emergency brake before towingis not covered under warranty.3. Pump the towed vehicle’s brake pedal several times, torelease the stored vacuum in the power brake system.CAUTIONAlways release the stored vacuum in the towedvehicle’s power brake system before towing — pumpthe brake pedal several times.Depending on the make and model of the towedvehicle, it may be necessary to pump the brake pedalrepeatedly to release the vacuum.If the vacuum is not released, the supplementalbraking system will apply excessive braking forcewhen it is activated, which will cause severe tire and/or brake system damage to the towed vehicle.Prepare the vehicles for towing1. First, connect the tow bar to the motorhome and thetowed vehicle.Then, according to the manufacturer, make all adjustments necessary to prepare the vehicle for towing.These adjustments may include: turning the ignitionkey to the ‘tow’ position; pulling fuses; disconnecting thebattery; and setting the transmission to a particular gearor in a particular sequence.Refer to the owner’s manual or call the dealership forvehicle-specific information.CAUTIONTo prevent the towed vehicle from rolling, connectthe tow bar to both vehicles before shifting the towedvehicle’s transmission into the proper gear for towing.Step BAttach the pedal clamp and air cylinderNote: the pedalclamp will not fit thebrake pedals of asmall number of latemodel Volkswagenvehicles, such as the2 0 07 Vo l k s w a g e nGolf. A photo of the 2007 Golf brake pedal is shown tothe right.Use the optional 9329-VW replacement pedal clampfor these vehicles.1. Slide the driver’s seat back, as far as it will go.2. Verify that the pedal clamp is right side up, as shownin Figure 1 — the arrow on the sticker will point “Up” whenthe pedal clamp is properly positioned.continued on next pageFigure 2Figure 12

OperationCAUTIONAttach the pedal clamp and air cylindercontinued from preceding page3. Pull the hairpin clip (Figure 1) out, then lift the slottedarm (Figure 1) up and out of the way.4. Move the pedal clamp over the brake pedal. Then holdthe clevis (Figure 2) and pull back on the spring post(Figure 2), until the tabs under the pedal clamp are wideenough to clear the brake pedal.5. Fit the pedal clamp onto the brake pedal, so that allfour tabs are hooked around it (Figure 3). Then releasethe spring post.Note: on the initial fitting, it may be necessary to adjustthe tabs on the pedal clamp — use pliers to bend any orall of the tabs so that they hook around and under thetowed vehicle’s brake pedal.Once the tabs have been adjusted to a specific brakepedal, 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 fitting. Verifythat all four tabs are hooked around and under the brakepedal. If necessary, bend the tabs to fit, as describedabove.The air cylinder must be pulled back when it is connected, in order to create sufficient spring tension tokeep 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 brake pedalcontinuously, which will cause excessive brake wear,brake system damage and/or other consequential, nonwarranty damage.If necessary, shorten the reach of the air cylinder,as described above, until it must be pulled back tocontinued on next pageCAUTIONMake certain that all four tabs on the pedal clampare securely hooked around the brake pedal.If the tabs are loose when the vehicle is towed,the pedal clamp can rotate out of position and holdthe brake pedal down, even when BrakeMaster is notactivated, which will cause tire and/or brake damage,or other consequential, non-warranty damage.Figure 36. Swing the slotted arm back over the spring post, fitthe spring post through one of the slots (Figure 3), andreattach the hairpin clip (Figure 3).7. Now that the pedal clamp is in place, attach the adjustable arm to the mounting post — insert the safety pinthrough the mounting post and adjustable arm, as shownin Figure 4. Then fit the loop at the end of the hasp (Figure5) over the end of the safety pin.Note: the mounting post may be attached to a seatadapter, near the front of the driver’s seat, or it may beattached to an anchor plate under the driver’s seat.Whether it is attached to an adapter or a plate, thefollowing instructions are identical.8. When it is connected, the air cylinder must be pulledback toward the mounting post, in order to keep the weightof the cylinder off the brake pedal.If necessary, shorten the reach of the air cylinder —remove the two bolts and nylon nuts (Figure 4) attachingthe cylinder to the adjustable arm (Figure 4). Slide theair cylinder down the adjustable arm until the end of theadjustable arm must be pulled back to attach it to themounting post. Then replace the bolts and nylon nuts.Figure 4Figure 53

OperationAttach the pedal clamp and air cylindercontinued from preceding pageconnect it to the mounting post.If the vehicle is equipped with pedal presets, notethe original position of the brake pedal when theBrakeMaster air cylinder and pedal clamp were installed, and return to that position before towing thevehicle.If the brake pedal is not at the original installedposition when the vehicle is towed, the air cylindermay be activated constantly, which will damage thebrake system and/or electrical system, and may causebrake or electrical system failure, as well as other nonwarranty damage.Step CConnect the air line,patch cord and break away system1. Connect the male quick coupler at the end of the airline on the air cylinder (Figure 5) to the female quick coupler (Figure 6) mounted inside the towed vehicle, on thedriver’s side. (See “Using the quick couplers” for instructions on how to connect the couplers.)2. Connect the patch cord (the six-foot length of air lineand wiring covered in blue plastic — see page 1) betweenthe two vehicles — both the air line quick couplers and themotorhome monitor bullet connectors.To connect or disconnect the bullet connectors, pushor pull them together or apart.3. To protect the couplers during towing, slide the weathersleeves (Figure 7) forward and over the couplers.Note: when you slide the weather sleeves forward, holdthem at the end farthest away from the quick couplers.The couplers could be disconnected if you hold the otherend.4. Connect the break away cable — clip the steel cableincluded with the BrakeAway system to the break awayring (Figure 8) on the break away switch. Clip the otherend of the steel cable to the rear of the motorhome, closeto the center.Note: the BrakeAway system is included with the BrakeMaster 9060 and 9160; it is an optional accessory for the9100.When connecting the break away system, alwaysmake certain that the following conditions are met: Connect the cable at the rear of the motorhome,close to the center. Connecting the cable toward either side of the motorhome may cause the break awaypin to be pulled when the motorhome turns, activatingthe break away system. Be sure there are no obstructions which wouldprevent the cable from pulling freely away from thebreak away switch. Do not wrap the cable around4anything — doing so could keep the cable from pulling the break away pin, preventing the system fromactivating in a break away. Make certain the cable is the correct length The cable must be long enough to prevent thebreak away pin from being pulled out duringnormal towing — make certain there is enoughslack to allow for sharp turns. If the cable is notlong enough, the break away system will activate even though the towed vehicle has not detached. The break away cable must be longer than thesafety cables. This will prevent the break awaysystem from activating if a component of thetowing system has separated, but the towed vehicle is still held by the safety cables. Make certain that the cable is not too long — itshould not hang down to the extent it may catchon obstructions, or drag on the ground. Thismuch slack could allow the cable to be pulled inadvertently, activating the break away system. If you have a telescoping tow bar, allow enoughslack for the tow bar arms to be fully extended. Except to test the system, leave the break away pinin place, even when the vehicle is not being towed.As soon as the pin is pulled, the break away systemcontinued on next pageFigure 6Figure 7Figure 8

OperationConnect the air line,patch cord and break away systemcontinued from preceding pagewill be activated. Until the pin is replaced, the breakaway system will run constantly, which will drain thevehicle's battery.Removing the pin will also expose the interior ofthe break away switch to damage from the elements.If the components of the switch are corroded, theswitch may only function intermittently or not at all.5. Charge the break away air reservoir —Note: the BrakeAway system is included with the BrakeMaster 9060 and 9160; it is an optional accessory for the9100.For motorhomes with air or air over hydraulicbrakes (BrakeMaster 9100 and 9160) — with the motorhome engine on, the air compressor completely chargedand the parking brake released, depress the brake pedalfor 15 seconds — apply firm pressure.For motorhomes with hydraulic brakes (Brake Master 9060) — start the motorhome and allow the air compressor to run until it shuts off. Then apply the motorhomebrakes and hold the brake pedal down.The break away air reservoir must be charged,as described above, every time the motorhome andtowed vehicle are connected.If the air reservoir is not charged, the break awaysystem will not apply braking pressure if the towedvehicle separates from the motorhome, which maycause property damage, personal injury or evendeath.Disconnecting the air cylinder1. Slide the driver’s seat back, as far as it will go.2. Detach the adjustable arm from the mounting post (Figure 4) by removing the safety pin (Figure 4).3. Remove the pedal clamp from the brake pedal — pullthe hairpin clip (Figure 3) from the spring post (Figure3).4. Swing the slotted arm (Figure 1) up and out of theway.5. Hold the clevis (Figure 2) and pull back on the springpost until the tabs under the pedal clamp are wide enoughto clear the brake pedal, then lift the pedal clamp up.The air cylinder will obstruct the towed vehicle’spedal controls. After towing, and before driving thevehicle, remove the air cylinder.5

Test the systemTest the BrakeMaster system, as described below,each time before towing.Since this section is also a list of each connection stepin sequence, you can use it as a quick reference checklist,once you understand how to connect and operate yourBrakeMaster. (For more detailed connection information,refer to the appropriate step under “Operation.”)CAUTIONAlways release the stored vacuum in the towedvehicle’s power brake system before towing — pumpthe brake pedal several times.Depending on the make and model of the towedvehicle, it may be necessary to pump the brake pedalrepeatedly to release the vacuum.If the vacuum is not released, the supplementalbraking system will apply excessive braking forcewhen it is activated, which will cause severe tire and/or brake system damage to the towed vehicle.1. First, connect the tow bar to the motorhome and thetowed vehicle.2. Then, according to the manufacturer, make all adjustments necessary to prepare the vehicle for towing.These adjustments may include: turning the ignitionkey to the ‘tow’ position; pulling fuses; disconnecting thebattery; and setting the transmission to a particular gearor in a particular sequence.Refer to the owner’s manual, or call the dealership forvehicle-specific information.CAUTIONTo prevent the towed vehicle from rolling, connectthe tow bar to both vehicles before shifting the towedvehicle’s transmission into the proper gear for towing.3. Release the towed vehicle’s emergency brake.4. Next, connect all components of the braking system — Attach the air cylinder to the brake pedal and mountingpost (or seat adapter). Connect the male quick coupler from the air cylinderto the female quick coupler mounted in the driver’s sideof the passenger compartment. Connect the patch cord between the two vehicles —both the air line quick couplers and the motorhome monitor bullet connectors. Clip one end of the steel break away cable to the breakaway pin; clip the other end of the cable to the rear of themotorhome, close to the center.5. For motorhomes with hydraulic brakes (BrakeMaster 9060) — turn the motorhome engine on, and leave itrunning.For motorhomes with air or air over hydraulicbrakes (BrakeMaster 9100 and 9160) — block the motorhome wheels and turn the motorhome engine on. Afterthe air compressor is completely charged, release theparking brake.66. Confirm the proper operation of the braking system:depress and hold the motorhome brake pedal down.At the towed vehicle, the air cylinder shaft and pedalclamp will extend.Then, release the brake pedal. The air cylinder shaftand pedal clamp will retract.7. Confirm that the motorhome monitor LED is functioningproperly: the LED will turn on as the motorhome brakepedal is depressed, and turn off when the brake pedal isreleased.CAUTIONIf the LED does not turn on and

Golf. A photo of the 2007 Golf brake pedal is shown to the right. Use the optional 9329-VW replacement pedal clamp for these vehicles. 1. 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 .

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