Instruction Manual

ManualsBrandsBlue Ox ManualsFor the carBX88144

Pender, Nebraska 68047 • Phone 402-385-3051 • Fax 402-385-3360 • www.blueox.com

BX88125 & BX88144

TOAD STOP

VAC BRAKE

Instructions for Supplemental Braking Systems.

BX88125 designed for gas powered Coaches.

BX88144 designed for diesel powered Coaches.

THE FIRST NAME IN REMOTE BRAKING SYSTEMS

NOTICE: IF YOU ARE NOT AN EXPERIENCED MECHANIC OR INSTALLER, PLEASE REFER TO THE

COMPLETE INSTRUCTIONS INCLUDED WITH VAC BRAKE

The ToadStop brake system applies a constant pressure to the toad vehicle's brake pedal, that can be adjusted to each

individual toad vehicle.

Customer supplied tools & supplies

Razor knife, silicone spray lubricant, 12VDC tester, drill & bits: (1/8", 1/4", 5/8”), drill punch, wire stripper/crimp tool, pliers:(standard, long nose, wire

cutter), screw drivers:(Phillips, slotted small & regular), wrenches:(10mm, 3/8", 7/8", 15/16", adjustable), 1/4" drive & 7/16"socket. Supplies: electrical

tape, butt connectors, shielded spade connectors, wire ties, misc. screws, hose adapters (for our 3/8" vacuum hose, supplied, to your size on the RV or

Toad).

INSTALLATION INSTRUCTIONS

1. TOAD VEHICLE INSTALLATION

MECHANICAL INSTALLATION OF COMPONENTS: Fig. 1

a. Remove rubber pedal cover and drill 1/8” hole in the face of the brake pedal frame at its lowest point. For vehicles with continuous power assist

brakes, do not drill into brake pedal frame. Use brake pedal assembly (item 8) above the brake pedal frame. The lower the assembly is placed

on the pedal frame, the more force that is applied. In the unlikely event more force is needed, drill the hole in the brake pedal frame.

b. Mount the cable pulley on the ﬂ oor behind the brake pedal with two self drilling screws provided, aligning the cable for the most efﬁ cient pull back.

c. Mount the vacuum actuator in a suitable place under the hood in the engine compartment with 13" cable ties. Making sure to position actuator box

so that the docking slot is facing towards the driver's side. (Locate unit away from hazards and hot spots.)

d. Route the cable housing through an existing hole through the ﬁ rewall, or if a hole cannot be found, drill a 3/8" hole through the ﬁ rewall and push the

3/8" grommet in place. If the grommet is used, the docking ﬁ tting that is on the cable assembly, will need to be removed for the cable housing to go

through. Reattach the docking ﬁ tting once the cable housing is pushed through, then slide the cable through the housing, making sure the ball end

is towards the docking ﬁ tting.

e. Attach the docking ﬁ tting to the actuator box and replace the plastic plug to secure the ﬁ tting. Remove the box top and attach the cable end to the

hole on the end of the pull arm. Replace the plastic plug that goes on the pull arm, so the cable end will not slip out.

f. Pull the cable through the hole on the brake pedal removing all slack. Push the cable stop up to the brake pedal and tighten.

TOAD VACUUM HOSE INSTALLATION: Fig. 2 & 4 - For vehicles with continuous power assist brakes, do NOT perform steps C

and D.

a. Install two 3/8” hose barb ﬁ ttings and one threaded plug to the vacuum reservoir and place it in a suitable area in the engine compartment (locate

unit away from hazards & hot spots).

b. Cut a piece of vacuum hose long enough to attach to one hose barb ﬁ tting on the reservoir to the hose barb ﬁ tting on the vacuum actuator box. Cut

this hose and install a plastic vacuum tee as shown in Fig.2.

c. Remove the vacuum hose from the original power booster check valve of the towed brake system, place the kit check valve and “T” assembly in

this line, with the black side facing away from the power booster and towards the engine vacuum ﬂ ow. Fig.2 & 4

d. Install the vacuum hose from the remaining push on ﬁ tting of the reservoir to the “T” connection in previous step.

Serial No.

Page 1 of 10 292-5809 Rev. C 2/21/11

Summary of content (10 pages)

PAGE 1
Serial No. BX88125 & BX88144 TOAD STOP®VAC BRAKE® Instructions for Supplemental Braking Systems. BX88125 designed for gas powered Coaches. BX88144 designed for diesel powered Coaches. THE FIRST NAME IN REMOTE BRAKING SYSTEMS NOTICE: IF YOU ARE NOT AN EXPERIENCED MECHANIC OR INSTALLER, PLEASE REFER TO THE COMPLETE INSTRUCTIONS INCLUDED WITH VAC BRAKE® The ToadStop brake system applies a constant pressure to the toad vehicle's brake pedal, that can be adjusted to each individual toad vehicle.
PAGE 2
TOAD WIRING INSTALLATION: Fig. 7 & 10 a. Connect one wire from the Vac Brake® solenoid to a suitable ground. (either wire) b. Install the dash switch in an inconspicuous and easy to reach place, on the center of the dash, to the right of the driver. c. Connect the remaining wire of the solenoid to the middle pin of the dash switch. Fig. 10 d. Connect an ignition “HOT” 12VDC feed wire to the terminal on dash switch as shown in Fig. 10. e.
PAGE 3
wire that is closest to the brake switch to tab 87 on the relay, making sure to connect with a wire that goes to the wiring connector on the front of the vehicle. Then connect a wire from the other end of the cut wire to tab 30 on the relay. Connect a wire from the car's fuse panel (12V IGNITION) to tab 86 on the relay. Tab 85 needs to go to a good solid ground connection. When NOT using the relay, connect a wire from the wiring connector to the "cold" side of the brake switch. b.
PAGE 4
c. Connect a wire from the cold side of the RV’s brake light switch to upper left terminal of the switch. d. Connect a wire from a constant 12 VDC power source (generally from the fuse panel) to the upper right terminal of the switch. e. Connect the center terminal of the RV dash switch to a wire that runs to the RV wire receptacle on an unused pin, across the tow bar to the activation signal wire of the solenoid on the Vac Brake®.
PAGE 5
SIZING THE VACUUM HOSE AND ELECTRICAL CONNECTIONS ACROSS TOW BAR a. RV b. c. With the toad vehicle connected to the tow bar, find the minimum length of the breakaway lanyard by measuring from the anchor point on the (as close to center as possible) to the breakaway switch. Record this measurement as X= Find the maximum length of the breakaway lanyard by disconnecting the tow bar and leaving the tow cables connected. Slowly back up the toad until the cables capture it.
PAGE 6
© 2005, 06, 11 Blue Ox Division, Automatic Equipment Mfg. Co. • One Mill Road, Industrial Park Pender, Nebraska 68047 • Phone 402-385-3051 • Fax 402-385-3360 • www.blueox.com Page 6 of 10 292-5809 Rev.
PAGE 7
Page 7 of 10 292-5809 Rev.
PAGE 8
RV SIDE TOAD SIDE + RV FUSE PANEL (CONSTANT) BREAK AWAY SWITCH _ 12 VOLT FUSE PANEL CONSTANT TOW ANTITHEFT "ON" TOAD BATTERY MOM. TEST UNLIGHTED SWITCH 12 VOLT FROM IGNITION CONNECTION ACROSS TOWBAR RV BRAKE SWITCH LIGHTED SWITCH RV DASH TOAD BRAKE SWITCH GROUND VEHICLE BRAKE LIGHTS RELAY CAR FUSE PANEL (IGNITION) SYSTEM WIRING DIAGRAM CUT BRAKE WIRE THAT IS HOT WHEN BRAKE IS APPLIED FIG. 10 © 2005, 06, 11 Blue Ox Division, Automatic Equipment Mfg. Co.
PAGE 9
IMPORTANT: Use only genuine factory replacement parts on your braking system. Do not substitute homemade or nontypical parts. If parts are lost or in need of replacement, for your safety and the preservation of your braking system. Order replacement parts through your nearest Blue Ox dealer or distributor. Parts List Ref. No. 1 2 4 5 *6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 *29 30 31 32 33 34 35 36 Part No. Description 62-3474 ....................................................
PAGE 10
© 2005, 06, 11 Blue Ox Division, Automatic Equipment Mfg. Co. • One Mill Road, Industrial Park Pender, Nebraska 68047 • Phone 402-385-3051 • Fax 402-385-3360 • www.blueox.com Page 10 of 10 292-5809 Rev.