Owner’s Manual - Roadmaster Inc. · rectly — the contact point at the bottom of the socket...

Towing and Suspension Solutions ROADMASTER,Inc.•6110NE127thAve•Vancouver,WA98682

800-669-9690•fax360-735-9300•roadmasterinc.com85-3476rev.0208/08©2008ROADMASTER,Inc.

Owner’s Manual

Partnumber8800

Entire contents of manual must be read by owner

The AddaBRAKE serial number… …is on a label on the underside of the unit. Youwill need this numberwhen you fill out your productregistrationcard. Write down the serial number in the space belowandretainforfuturereference…

Serialnumber:

ThismanualhasbeenpreparedtoacquaintyouwiththeinstallationandoperationofyourAddaBRAKE,andto provideyouwithimportantsafetyinformation.

Readyourowner’smanualcovertocover.UnderstandhowtoinstallandoperateyourAddaBRAKE,andcare-fullyfollowtheinstructionsandsafetyprecautions. YourAddaBRAKEhasaone-yearlimitedwarranty.Toqualifyforyourwarranty,filloutandreturntheenclosedproductregistrationcardwithin30daysofpurchase.As a bonus, we’ll extend your warranty to a total of two years at no additional cost, if we receive the product registration card within 30 days of purchase. Wethankyouforyourpatronageandgreatlyappreciateyourdiscerningtaste.

WELCOME TO THE ROADMASTER FAMILY!

IMPORTANT NOTICE!Safety Definitions

Thismanualcontainsinformationthatisveryimportanttoknowandunderstand.Thisinformationisprovidedforsafetyandtoprevent equipment problems.Tohelprecognizethisinformation,observethefollowingsymbols:

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 situ-ation 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.

AddaBRAKE specificationsHeight ...........................................................12inchesWidth........................................................ 11.25inchesLength ...........................................................16inchesWeight ...................................................... 15.5poundsVoltage ...................................................... 12voltsDCOperatingtemperaturerange ...............................-2°to+150°F(-19°to+66°C)Lengthofstandardpowercord .....................42inchesMaximumamperagedraw .......................... 10.8ampsIdleamperagedraw ............................................ 11mAApproximatemaximumairpressure .................. 60psiMaximumforceextendedonbrakepedal ...... 106lbs.MinimumspaceAddaBRAKEcanfit ............16inches

TABLE OF CONTENTSSpecifications ....................................insidefrontcoverSafetydefinitions ..............................insidefrontcoverComponents ............................................................... 2Wiringdiagrams ......................................................... 3

Initial InstallationBeforeyoubegintheinitial installation (installer’schecklist) ...........................................4-5Initial installation ................................................... 6-11 Installthebreakawaysystem ............................... 6 Modificationstothe towedvehicle’slightingsystem ......................6-7 Installthemotorhomemonitor wiringharnessinthetowedvehicle ...............7-8 Attachthebrakesignalwire ...............................8-9 Attachthefirewallgrommet; attachthewiringconnectors ....................... 9-10 InstallthemotorhomemonitorLED ..................... 10 Testthebrakingsystem ................................. 10-11

Day-to-Day OperationAttachthepedalclamp ....................................... 12-13Adjustthefeetandtheseatpad ........................ 13-14

Pluginthepowercord ....................................... 14-15Testandadjustpositioning; depletethevacuuminthepowerbrakes ............ 15Setthebrakepressure ............................................ 16Connectthewiringharness; testthebreakawaysystem ............................ 16-17Connectthemotorhomemonitorpatchcord ........... 17Testthebrakingsystem ...................................... 17-18

Protection ModesExtendedbrakingprotection .................................... 18Respondingtoanaudioalert .................................. 18

Quick Reference ChecklistConnectingAddaBRAKE .................................... 19-20DisconnectingAddaBRAKE ..................................... 20

Troubleshooting .................................................. 21-22Ford‘neutraltow’vehicles .................................. 23-24Optionalequipment .................................................. 25Limitedwarranty ...................................................... 26Index ........................................................................ 27

Read all instructions before installing or oper-ating AddaBRAKE. Failure to understand how to install or operate AddaBRAKE could result in prop-erty damage, personal injury or even death.

Not for use on older vehicles without power brakes. AddaBRAKE is designed to work with ve-hicles that have a power brake system (even though the power brakes are not activated while towing). Using AddaBRAKE on vehicles that do not have power brakes will result in over-braking and severe non-warranty brake damage.

Do not install AddaBRAKE in a vehicle with an ‘active’ braking system. ‘Active’ (or, ‘continuous power assist’) braking systems are a safety feature on some new vehicles. This feature allows the brakes to always have pow-er, even with the ignition off. The only supplemental braking system that ROADMASTER manufactures for these vehicles is BrakeMaster, with the addition of a Brake Pressure Reducer (part number 900002). If any ROADMASTER supplemental braking sys-tem other than a BrakeMaster with a Brake Pres-

sure Reducer is installed, the vehicle will brake with excessive force, which will damage the tires. Other non-warranty damage may also occur. It is the owner’s responsibility (or if profession-ally installed, the installer’s responsibility) to de-termine if the vehicle being equipped with supple-mental brakes has an active braking system — refer to the owner’s manual, the vehicle manufacturer or the dealership. ROADMASTER expressly disallows any and all claims relating to tire damage, brake damage, or any other damage to vehicles with ‘active’ braking systems caused by: 1) installation of any ROAD-MASTER supplemental braking system other than BrakeMaster; or 2) failure to install a Brake Pres-sure Reducer with the BrakeMaster.

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COMPONENTS

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part number description

1 9329 ....................brakepedalclamp 2 n/a .......................aircylindershaft 3 n/a .......................pressuregauge 4 n/a .......................regulatorcontrolknob 5 n/a .......................airreliefbutton 6 n/a .......................testbutton 7 650996.................adjustableseatpad (handleassembly) 8 450952.................adjustmentknob 9 450105.................adjustablefeet 10 450103.................12-voltpowercord 8

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Itemsnotshowntoscale.Optionalequipmentislistedinthe“OptionalEquipment”section.

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part number description

11 650906.................AddaBRAKEwiringharness 12 650900.................breakawaywiringharness 13 8602 ....................breakawaycable 14 650898.................breakawayswitch 15 650906-01 ...........brakesignalwire 16 300065-00 ...........motorhomemonitorLED 17 9325 ....................audiosignalcircuitboard 18 450008.................motorhomemonitorpatch cord(notpictured)

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1. ALWAYS CHECK THE ROADMASTER WEB SITE — www.roadmasterinc.com—forvehicle-specificinforma-tion.Select‘Vehicle-SpecificInfo,’enterthemotorhomeandtowedvehiclemake,modelandyear, thenselect‘BrakingSystems.’

2. If the battery must be disconnectedfortowing,a12-voltoutletkit(partnumber9332)andastoplightswitchmustbeinstalled.ROADMASTERmanufacturesstop light switch kits for a number of vehicles; tosee if one is available for any specific vehicle, visitwww.roadmasterinc.com and select ‘Vehicle-SpecificInfo,' enter the vehiclemake,model and year, thenselect‘BrakingSystems'andscrolldownthepage.

Note: if a stop light switch kit is listed on the web site 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 12-volt outlet kit and a stop light switch are still required; the Brake-Lite Relay (see below) is not required.

3. If fuse(s) must be removed from the vehicle be-fore it can be towed—verifythatremovingthefuse(s)willnotdisruptpowertoAddaBRAKE,orotherwiseaf-fecttheinstallationoroperation.

4. Check the towed vehicle’s 12-volt outlet for correct power —AddaBRAKEispoweredthroughthe12-voltoutlet,withthe ignitionkeyturnedtothe“tow”position.However,somevehiclesonlyhavepoweratthe 12-volt outletwhen the engine is running.Beforeyou begin the initial installation, verify that you havepower at the towed vehicle’s 12-volt outlet with theignitionkeyturnedtothe“tow”position.

Ifthereisnopower,youcaninstalltheoptional12-voltoutletkit(partnumber9332).Wheninstalled,thiskitwill providepower to the12-volt outletevenwhentheengineisoff.

5. Check the 12-volt outlet sockettomakecertainthat:a)thesockethasbeenwiredcorrectly;andb)thesocketisnotcorroded.

a. Make certain that the socket has been wired cor-rectly— thecontactpointat thebottomof thesocketshouldbepositive,andtheoutershellaroundthetopofthesocketshouldbenegative.

If the socket’s positive and negative connections have been reversed, the fuse in the AddaBRAKE power cord will blow when the cord is plugged into the 12-volt outlet.

b. Make certain that the socket is not corroded or otherwise damaged—acorrodedsocketmaynotprovide constant power to AddaBRAKE, whichmay

Before you begin the initial installation…causeintermittentoperation.

Ifthesocketiscorrodedordamaged,youcanin-stalltheoptional12-voltoutletkit(partnumber9332).When installed, thiskitwillprovideconstantpower toAddaBRAKE.

If the towed vehicle has a single 12-volt outlet which has been used to heat a cigarette lighter plug, install the optional 12-volt outlet kit for the Adda-BRAKE power supply. Using a cigarette lighter plug in a 12-volt socket will corrode the contact points. The socket will not supply sufficient voltage to be used as the Adda-BRAKE power source — AddaBRAKE may not oper-ate, or may only operate intermittently.

6. The circuit at the towed vehicle’s 12-volt outlet must be rated at NO LESS THAN 15 AMPStopowerAddaBRAKE.Checkthefuseattheoutlet—ifthefuseisratedat15ampsorhigher,thecircuitisadequatetopowerAddaBRAKE.Ifthefuseisratedatlessthan15amps,installtheoptional12-voltoutletkit(partnumber9332).When installed, this kit will provide power toAddaBRAKE.

If the circuit at the 12-volt outlet is rated at less than 15 amperes, install the optional 12-volt outlet kit. Depending on the available current during tow-ing, AddaBRAKE may not function, or may function incorrectly, without at least 15 amps.

If the circuit is rated at less than 15 amps, do not simply replace the outlet’s fuse with a higher-am-perage fuse. This will cause the wiring to overheat, which can cause wiring damage, an electrical fire, or other consequential, non-warranty damage. Failure to follow these instructions may cause property damage, personal injury or even death.

7. Check the towed vehicle’s brake lights—Adda-BRAKEmust functionwith the ignition key turned tothe“tow”position.However,somevehicles’brakelightsonly operatewith the key turned to the “on” position.Checktoseeifthisisthecase:turntheignitionkeytothe“tow”position,applythebrakes,andchecktoseeif thebrake lights illuminate. If thebrake lightsdonotilluminate, a two-prong stop light switch and 10-ampfusemustbeinstalled.

Note: check the owner’s manual to see if the vehicle is equipped with an “automatic shut down” feature. If

continued on next page

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Before you begin the initial installation…continued from preceding page

this is the case, ensure that the vehicle is not in auto-matic shut down mode before performing this test.

ROADMASTERmanufacturesstoplightswitchkitsforanumberofvehicles;toseeifoneisavailableforanyspecificvehicle,visitwww.roadmasterinc.comandselect ‘Vehicle-Specific Info,’ enter the vehiclemake,model and year, then select ‘Braking Systems' andscrolldownthepage.

Note: if you must install a Brake-Lite Relay — see step 9, below — a stop light switch is not required.

8. If the towed vehicle has a magnetic tow light system—modificationswill benecessary, inorder topermanentlyattachthebrakesignalwire.RefertoStepDunder“Initial Installation”—“Attachthebrakesignalwire,”step2c.

9. An optional Brake-Lite Relay may be required. Seepageseven for instructionsonhow todetermineiftherelaymustbeinstalled.

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.

10. If the towed vehicle will be (or has been) wired for towing—diodesmustbeattachedtothewires.

Theelectricalcircuitthatturnsthetowedvehicle'sbrakelightsonandoffalsoturnsAddaBRAKEonandoff. If diodes are not attached, electrical feedbackthrough thebrake lightwirewill preventAddaBRAKEfrom releasing braking pressure.AddaBRAKEwill beactivated with the brake lights, but will not releasebrakingpressureuntiltheextendedbrakingprotectionmode overrides the brake signal, after approximately15seconds.

If the vehicle will be wired for towing, diodes must be attached in order for AddaBRAKE to re-lease the towed vehicle's brakes in tandem with the motorhome. If diodes are not attached, AddaBRAKE will apply braking pressure for approximately 15 seconds each time the motorhome brakes are ap-plied, regardless of when the motorhome brakes are released. Damage to the towed vehicle's braking system, as well as other consequential damage, may occur.

Additionaldiodesarenotrequiredif…

• …aBrake-LiteRelay(partnumber88400)mustbeinstalledinthetowedvehicle;or • …anon-intrusivewiringmethodisselected—eitherataillightwiringkit(partnumber155)ormagnetictowlights(partnumber2100or2120).

Awiring kitwith diodes is available fromROAD-MASTER — the Universal Wiring Kit, part num-

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ber 154. Additional diodes may also be purchasedseparately. Wiring diagrams are under ‘Support’ atwww.roadmasterinc.com.

In addition to wiring and connection instructions, this section contains information about the components of yoursupplementarybrakingsystem,andhowthey function.For that reason, read thissection,even ifyouwillnotbeinstallingthesecomponentsyourself.

Step AInstall the break away system

“Breakaway”systemsaresecondarysafetydevices,required by law inmany states,whichwill brake thetowedvehicle if itseparates(“breaksaway”) fromthemotorhome.

1. Mountthebreakawayswitch(Figure1)atthefrontofthevehicle,onthedriver’sside.Chooseanareayoucaneasilyreach,withasurfaceofsufficientstrengthtoholdtheswitchfirmlyinplace,sothatthebreakawaypin(Figure1)willpullfreelyfromtheswitch.Mounttheswitchinahorizontalposition,withthebreakawaypinfacingtowardthemotorhome.

Ensurethatthebreakawaypincanbepulledfree-ly away from the towed vehicle,without any obstruc-tions.

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, per-sonal injury or even death.

2. Thebreakawaywiringharness(Figure1)connectsthebreakawayswitchtoAddaBRAKE.Itwillberoutedthroughthefirewall,onthedriver’sside.

Lookforapre-existingholeinthefirewall(or,ifthereis sufficient space, a pre-existing grommetwith otherwiring)close to the flooron thedriver’sside, to routethebreakawaywiringharnessthroughthefirewall.

Note: the motorhome monitor wiring harness (Step C) and the brake signal wire (Step D) will also be routed through this hole.

Ifthereisnopre-existingholeorgrommetwithsuf-ficientspace,drilla1/2"holethroughthefirewall.

Drill fromtheenginecompartmentorfromthein-terior of the vehicle, whichever ismore convenient.Beforedrilling,makecertainyouwillnotdamageanycomponentsontheothersideofthefirewall.

3. Routethewiringharnessfromthebreakawayswitchto the firewall (or, from the firewall to thebreakawayswitch,whicheverismoreconvenient),avoidinglines,hoses,movingpartsor“hot”componentssuchasex-haustsystems.

Whereappropriate,usewiretiestosecurethebreak

Figure 1

INITIAL INSTALLATION

awaywiringharness.

Atthefrontofthevehicle,connectthewiringhar-nesstothebreakawayswitch.

YouwillconnectthebreakawaywiringharnesstoAddaBRAKEinalaterstep.

Step BModifications to the

towed vehicle’s lighting system Asupplementalbrakingsystemwillaffecttheopera-tion of the vehicle’s tow lighting system.Use the fol-lowinginformationtodetermineifoptionalaccessoriesmustbeinstalledinavehiclewhichhasbeenwiredfortowing — or, if no lighting systemhas been installed,whichsystemsareappropriate.

1. First, identify the type of brake and turn signalsin the vehicle. There are two types — combined orseparate.Inacombinedsystem(Figure2),thebrake


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Modifications to the towedvehicle’s lighting systemcontinued from preceding page

lightdoestheflashingfortheturnsignal;inaseparate system (Figure2), thereareamberor red turnsignallightswhichareseparatefromthebrakelights.

2. Next,testtoseeifthetowedvehicle’sbrakelightswillilluminatewiththeengineoff—turntheignitionkeytothe“tow”position,pressthebrakepedal,andcheckthebrakelights.

3. Basedonwhetherornotthebrakelightsilluminate,andthetypeofbrakeandturnsignals,therearethreepossibilities:1)thebrakelightsilluminateandthetowedvehicle has combined lighting; 2) the brake lights il-luminateandthetowedvehiclehasseparate lighting;or 3) thebrake lights donot illuminate.Choose fromtheappropriate list below to install eitheranoptionalaccessoryoranotherlightingsystem.

(If you choose to install a systemof diodes andrewire the vehicle’s turn signals, taillights and brakelights for towing, wiring diagrams are available atwww.roadmasterinc.com.)

1. If the brake lights illuminate and thetowed vehicle has combined lighting…

…oneofthethreealternativesbelowisrequired.

A. Asystemofdiodes(the vehicle’s turn sig-nals,taillightsandbrakelightshavebeenrewiredfor towing) with an op-tionalBrake-LiteRelay. (ThismethodcannotbeusedinFordvehicleswith ‘neutral tow’ kits.See “Ford ‘neutral tow’vehicles,”inthismanual,forwiringinstructions.) B. Install a “bulb andsocketset”(alsocalleda“taillightwiringkit,” partnumber155). C. Install a magnetictowlightsystem(partnumber2100or2120).

2. If the brake lights illuminate and thetowed vehicle has separate lighting…

…oneofthefouralternativesbelowisrequired.

A. Asystemofdiodes(thevehicle’sturnsignals,tail-lights andbrake lights havebeen rewired for towing)withanoptionalBrake-LiteRelay. (ThismethodcannotbeusedinFordvehicleswith

‘neutral tow’kits.See“Ford ‘neutral tow’vehicles,” inthismanual,forwiringinstructions.) B. Asystemofdiodeswith the diodes jumped.ThismethodisalsousedtowireFordvehicleswith‘neutraltow’kits.SeeFigure15. C. Installa“bulbandsocketset”(alsocalleda“taillightwiringkit,”partnumber155). D. Install amagnetic tow light system (part number2100or2120).

3. If the brake lights do not illuminate… …an optional stop light switchmust be installed.ROADMASTERmanufacturesstoplightswitchkitsforanumberofvehicles;visitwww.roadmasterinc.comforthemostcurrent listofavailablekits. Anyoneof thefollowingtowlightingsystemsmustalsobeinstalledwiththestoplightswitch: • asystemofdiodes(thevehicle’sturnsignals,tail-lightsandbrakelightshavebeenrewiredfortowing) • a “bulb and socket set” (also called a “taillightwiringkit,”partnumber155) • amagnetictowlightsystem(partnumber2100or2120)

Step CInstall the motorhome monitor

wiring harness in the towed vehicle When the components of themotorhomemonitorareinstalledandconnected,anLEDonthemotorhomedashboardwillilluminateeachtimeAddaBRAKEisac-tivated,confirmingthatthetowedvehicle’sbrakeshavebeenapplied.

Note: there are two lengths of black wire in this kit, each with a female bullet connector at one end. Use the short length of wire in this step.

1. Chooseamountingpointatthefrontofthevehicle,near the electrical socket, for the endof the harnesswiththefemalebulletconnector.Attachtheconnectorwithoneormoreoftheincludedwireties.Allowenoughslackso thatamalebulletconnectorcanbepluggedintoandoutof it.

Note: if there is an open terminal available on both electrical sockets, you can use the existing electrical cord to connect the monitor wiring between the two vehicles. This method eliminates a separate patch cord, included with AddaBRAKE for the same purpose. If you choose this method, cut the female bullet connector off, and attach the monitor wire to the open terminal on the towed vehicle’s electrical socket. Later, you will use the matching terminal on the motorhome’s electrical socket to complete the connection.



Figure 2

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Install the motorhome monitor wiring harness in the towed vehiclecontinued from preceding page

Note: if you choose this method, keep the patch cord. If a second towed vehicle is added later, it may not have an open terminal available on the electrical socket.

2. Oncethefemalebulletconnectorisattached,routethemonitor wiring harness through the engine com-partment, to the driver’s side of the firewall. Use thesame routeas thebreakawaywiringharness, if thatis convenient. As before, avoid lines, hoses,movingparts or “hot” components such as exhaust systems.Whereappropriate,usewire ties tosecure thewiringharnessinplace.

3. Routethemotorhomemonitorwiringharnessthroughthesameholeasthebreakawaywiringharness(StepA).

4. Next,locatethetowedvehicle’sbrakelightswitchand,witha test light, find the“cold”sideof thebrakelight switch — the “cold” side of the switch does notregister voltage unless the brakes are applied.Witha12-voltmeter,verify thatyouhave found12VDC+. Then,removethevehicle’sbrakelightfuse,locatedinthevehicle’sfusepanel.

Failure to remove the brake light fuse from the vehicle’s fuse panel may cause the vehicle’s theft deterrent system, or other electrical system indica-tors, to be activated if the brake pedal is depressed during the installation. This may require non-war-ranty repair to the vehicle.

5. Cutthebrakelightwire,afewinchesdownstreamfromthe“cold”sideofthebrakelightswitch.

If the Brake-Lite Relay is required…(seetheprevioussection—“Modificationstothetowedvehicle’slightingsystem”)

Install theBrake-LiteRelay now. The installationinstructionsareincludedwiththerelay.AftertheBrake-LiteRelayisinstalled,proceedtoStepD—“Attachthebrakesignalwire.”

Note: do not install the Brake-Lite Relay unless it is required. Refer to the previous section — “Modifica-tions to the towed vehicle’s lighting system.”

If the Brake-Lite Relay is not required…(seetheprevioussection—“Modificationstothetowedvehicle’slightingsystem”)

6. Ifnecessary,trimthemonitorwiringharness,then

attach themonitorwire to the brake lightwire, usingthesuppliedyellowbuttconnector.

7. Ensurethatthemonitorwiringharnesswillnotpres-entanobstacleorhazardto thedriverof thevehicle,or interferewiththeoperationofthevehicle.Useoneormorewire ties, if necessary, to secure thewiringharnessoutoftheway.

8. Reinstallthebrakelightfuse,whichyouremovedinstep4.

Step DAttach the brake signal wire

Thebrakesignalwire isattachedtothebrakelightwire(s)inthetowedvehicle’selectricalharness.Whenthe brake signal wire is connected to AddaBRAKE(alongwith theother componentsof thebrakingsys-tem), AddaBRAKEwill be activatedwhen the towedvehicle’sbrakelightsareactivated.

Note: the brake signal wire is a six-foot length of green wire, with a female bullet connector at one end.

1. Chooseaconvenientpointonthetowedvehicle’stow lightharness toattach thebrakesignalwire,andremovetheprotectiveloomcoveringthatsectionoftheharness.

2a. Ifthetowedvehiclehascombinedbrakeandturnsignallights(Figure2)…

• Cuttheyellowwire(leftturn/brake)ontheharness,and attach the endswith one of the supplied yellowbutt connectors (Figure3).Repeat for thegreenwire(rightturn/brake).

• Then,runasmalllengthofthesuppliedwirefrombothbuttconnectors(Figure3),andattachbothwirestotheinputsoftheincludeddiode(Figure3)withtwoofthesuppliedspadeconnectors.

2b. If thetowedvehiclehasseparatebrakeandturnsignallights(Figure2),theconnectionisthesameasabove,exceptthatonlyonewire(thebrakelightwire)isattachedtothediode…

• Withatestlight,determinewhichofthewiresinthetowlightharnessisthebrakelightwire—whenthetestlightisconnectedtothebrakelightwire,thetestlightwill illuminatewhen themotorhome’s brake pedal isdepressed.

• Cutthebrakelightwire,andconnecttheendswithoneoftheincludedyellowbuttconnectors.

• Then,runasmalllengthofthesuppliedwirefromthe butt connector, and attach thewire to the diodewith another spade connector. Use either one of thetwoinputs; leavetheotherinputempty. continued on next page


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Figure 3

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method(2a,above).

3. Usinganotherofthesuppliedspadeconnectors,at-tachthebareendofthebrakesignalwiretotheoutputofthediode(Figure3).

4. Routethebrakesignalwirethroughtheenginecom-partment, to the driver’s side of the firewall. Use thesame routeas thebreakawaywiringharnessand/orthemotorhomemonitorwiringharness, if that is con-venient. As before, avoid lines, hoses,moving partsor“hot”componentssuchasexhaustsystems.Whereappropriate, usewire ties to secure the brake signalwireinplace.

5. Routethebrakesignalwirethroughthesameholein the firewall as the break awaywiring harness andthemotorhomemonitorwiringharness.

6. Replacetheprotectiveloom,whichyouremovedinstepone.

Step EAttach the firewall grommet;attach the wiring connectors

1. Cutthroughtheincludedfirewallgrommet(Figure1)ononeside,andslideitoverthebreakawaywiringhar-ness,thebrakesignalwire,andthemotorhomemonitorwiringharness.Fitthegrommetintothe1/2"holeyoudrilledinthefirewall.Feedtheremaininglengthsofthebrakesignalwireand thebreakawaywiringharnessthrough thegrommet.Then, seal thegrommetwithasiliconesealant.

2. WhenAddaBRAKEisconnectedanddisconnected, continued on next page

Attach the brake signal wirecontinued from preceding page

2c.Ifthetowedvehiclehasmagnetictowlights…

Note: additional connectors and — depending on the application — additional wiring will be necessary to wire a magnetic tow light system.

• Peelbackasectionoftheprotectivecoveringneartheplugontheelectricalcable—enoughtouseatestlightonthewiringand,later,toattachtwobuttconnectors.Then,usingatestlight,findtheleftandrightcombinedbrakeandturnsignalwires.

• Cutoneofthecombinedbrakeandturnsignalwires,andattachtheendswithabuttconnector.Runasmalllengthofwirefromthebuttconnector,andattachafemalebulletconnectortotheendofthewire.

Attachamalebulletconnectortoanothersmalllengthofwire.Usingoneoftheincludedspadeconnectors,at-tachtheotherendofthewiretooneoftheinputsonthediode.

Repeatfortheotherbrakeandturnsignalwire.

Beforetowing,connectthemaleandfemalebulletconnectors.

• Trimtheprotectivecoveringovertheelectricalcable;wrapanyexposedwiringwithelectricaltape.

• Connecttoground—atbothvehicles,connectawiretoanygoodchassisground.Beforetowing,connectthegroundwireswithaseparatecable.

2d. Ifthetowedvehiclehasataillight(“bulbandsocket”)wiring kit…

• Makecertainthatagroundconnectionexistsbetweenthetowedvehicleandthemotorhome.Otherwise,thewir-ingisidenticaltothecombinedbrakeandturnsignallight

Attach the firewall grommet;attach the wiring connectorscontinued from preceding page

the AddaBRAKEwiring harnesswill be plugged intoand out of the connectors on the break awaywiringharnessandthebrakesignalwire.

Withthisinmind,chooseasuitablelocationfortheend of the break away harness and the end of thebrakesignalwire—bothconnectorsmustbewithineasyreach,butmustnotpresentanobstacleorhazard tothedriverofthevehicle,orotherwiseinterferewiththeoperationofthevehicle.

Ifnecessary,coilthebreakawayharnessand/orthebrakesignalwire.Then,attach themat thepointyouhaveselected,usingoneormoreoftheincludedwiretiestosecuretheminplace.

Step FInstall the motorhome monitor LED

Note: there are two lengths of black wire in this kit, each with a female bullet connector at one end. Use the long length of wire in this step.

Note: some motorhomes are manufactured with aux-iliary wires pre-strung from the rear of the motorhome to the dashboard, for aftermarket accessories such as this. Call the manufacturer.

1. Attachtheendoftheblackwirewiththefemalebul-letconnector to thebackof themotorhome,near theelectricalsocket.

Attach the connectorwithoneormoreof the in-cludedwire ties. Allow enough slack so that amalebulletconnectorcanbepluggedintoandoutof it.

Note: in Step C, you may have chosen to use open terminals on the electrical sockets to connect the

INITIAL INSTALLATIONmonitor wiring between the two vehicles. If this is the case, cut the female bullet connector off, and attach the monitor wire to the open terminal on the motorhome electrical socket.

2. Oncethefemalebulletconnectorisattached,routethewirefromthebackofthemotorhometotheunder-sideofthedashboard.Avoidlines,hoses,movingparts(slideouts, slidinggenerators, slidingbattery trays)or“hot” components such as exhaust systems.Whereappropriate, use wire ties to secure the wire to theundercarriage.

3. ChooseanareaonthedashboardtomounttheLED.Lookforamountingpointawayfrompre-existingwiresorcomponents,wheretheLEDcanbeeasilyseenbythedriver.

4. Drilla5/16"holethroughthedashboardatthepointyouhavechosen.Beforedrilling,makecertainyouwillnotdamageanycomponentsontheotherside.

5. CentertheLEDdecal(Figure4)overthehole,andpress itdown.Or,youmaychoose toomit thedecal,dependingonyourpreferences.

6. Fromthetopofthedashboard,slidetheLEDthroughthehole,wires first,until thebaseof thebulb(Figure4)isflushtothetopofthedash.

7. Fromtheundersideofthedash,fitbothofthewiresthroughthespeednut(Figure4).Thenpushthespeednutup,againstthedash,tosecuretheLEDinplace.

8. Usingoneormoreofthesuppliedwireties,attachtheaudiosignalcircuitboard(see“Components,”pagetwo)totheundersideofthedash,asclosetotheLEDaspossible.

9. Connecttopower—trimtheblackwire,whichyouroutedfromthebackofthemotorhome.(Savetheex-cess;youmayuse it in thenextstep.)Then,connectthe blackwire to both the red LEDwire and the redaudiosignalwire,usingtheincludedbuttconnector.

10. Connecttoground—connecttheblackwirefromtheLED, aswell as the blackwire from the audio signalcircuit board, to any good chassis ground, using theincluded ring terminal. (If necessary, use any excesswire from the preceding step to extend the length ofthetwogroundwires.)

Step GTest the braking system

Note: the motorhome and towed vehicle must be stationary for the system test, and ready for towing — all components of the braking system must be properly connected and receiving power. Then, according to the manufacturer, make all adjustments necessary to pre-


Figure 4

10

functions properly. Failure to follow these instructions may cause property damage, personal injury or even death.

4. Confirmtheproperoperationoftheextendedbrakingmode:depressandholdthemotorhome’sbrakepedaldown. TheAddaBRAKE air cylinder shaft and pedalclampwillextend.Afterapproximately15seconds,theaircylindershaftandpedalclampwillretract.

5. Confirmtheproperoperationoftheaudioalert:de-pressandholdthetowedvehicle’sbrakepedaldown.Afterapproximately20seconds,themotorhomemonitorwillactivatetheaudioalert.(Tocanceltheaudioalert,releasethetowedvehicle’sbrakepedal.)

6. Confirmthatthemotorhometurnsignalsdonotac-tivateAddaBRAKE.

An incorrect flasher speed may activate Adda-BRAKE unnecessarily, causing excessive brake wear or other consequential, non-warranty dam-age. If the turn signals activate AddaBRAKE, check the turn signal flasher rating — it may be inadequate for the motorhome-towed vehicle combination. If this is the case, replace the flasher with one rated at or above the number of bulbs in the motorhome-towed vehicle combination.

Test the braking systemcontinued from preceding page

pare 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.

Refer to the owner’s manual, or call the dealership or the manufacturer for vehicle-specific information.

1. ConnectAddaBRAKEaccordingtotheinstructionsinthenextsectioninthismanual—“Day-to-dayopera-tion.”

2. Confirmtheproperoperationofthesupplementalbraking system: depress and hold themotorhome’sbrakepedaldown.TheAddaBRAKEaircylindershaftand pedal clampwill extend (after approximately twoseconds).Then,releasethebrakepedal.Atthetowedvehicle, theAddaBRAKEair cylinder shaft andpedalclampwillretract.

If the vehicle will be (or has been) wired for tow-ing (as opposed to installing a taillight wiring kit or magnetic tow lights), diodes must be attached in order for AddaBRAKE to release the towed vehicle’s brakes in tandem with the motorhome. If diodes are not attached, AddaBRAKE will apply braking pres-sure for approximately 15 seconds each time the motorhome brakes are applied, regardless of when the motorhome brakes are released. Damage to the towed vehicle’s braking system, as well as other consequential damage, may oc-cur. Refer to step 10 under “Before you begin the initial installation” for additional information.

3. Confirmthatthemotorhomemonitorisfunctioning:theLEDwillilluminateafterthemotorhome’sbrakeped-alisdepressed(afterapproximatelytwoseconds),andstopilluminatingwhenthebrakepedalisreleased.

If the LED does not illuminate… …it may indicate that AddaBRAKE is wired incor-rectly. If AddaBRAKE is wired incorrectly, it will not brake the towed vehicle in tandem with the motor-home. Insufficient braking pressure will lengthen stopping distance, and may also cause a loss of vehicular control. Refer to the ‘Troubleshooting’ section (under ‘Electrical’) for possible causes. If AddaBRAKE has been incorrectly wired, identify and correct the mistake, then test to ensure that AddaBRAKE


11

DAY-TO-DAY OPERATIONThis section contains detailed operating instructions. Refer to this section until you become familiar with

eachstep.(BeforeconnectingordisconnectingAddaBRAKE,alsorefertothe“QuickReferenceChecklist”foradditionalwarningsandcautions.)

Determine if the vehicle to be towed is equipped with pedal presets and/or automatic seat adjust-ments. Proper installation 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 seat and/or brake pedal are not at the origi-nal installed position when the vehicle is towed, the pedal clamp may apply excessive braking force, which will damage the brake system and/or elec-trical system and may cause brake or electrical system failure, as well as other non-warranty dam-age. Failure to follow these instructions may cause property damage, personal injury or even death.

5. Presstheairreliefbutton(Figure5)tomakecertainthatallof theair in theAddaBRAKEair reservoirhasbeenreleased.Ifthereisairinthereservoir,continuetohold thebuttondownuntil theair is released—airinthereservoirwillpreventthecylinderfromextendingwhenyouconnectthebrakepedalclamptothetowedvehicle’sbrakepedal.

6. Continuetoholdtheairreliefbuttondown,andpullforwardonthepedalclamp,toextendtheaircylindershaft.Releasetheairreliefbutton. continued on next page

Step AAttach the pedal clamp

1. Connect andattach the towbar to both vehicles(according to themanufacturer’s instructions). Then,shift the towed vehicle’s transmission into the propergear for towing (alsoaccording to themanufacturer’sinstructions).

To prevent the towed vehicle from rolling, con-nect and attach the tow bar to both vehicles before shifting the towed vehicle’s transmission into the proper gear for towing.

2. Slidethedriver’sseatback,asfarasitwillgo.

3. Attach theadjustableseatpad toAddaBRAKE—screw theadjustment knob (see “Components,” pagetwo) through the seat pad and into either of the twoanchorholesatthebackofAddaBRAKE.(Youwillad-justtheseatpadinalaterstep.)

Note: depending on the available space in the towed vehicle, the adjustable seat pad may be eliminated, if that provides the best fit. Before attaching the seat pad, test-fit AddaBRAKE, according to step 4 below, to see if this is the case.

4. Now,positionAddaBRAKEbetweenthedriver’sseatandthebrakepedal,attheapproximatepositionitwillsitwhenconnectedtothebrakepedal.

Note: rubberized floor mats will cause AddaBRAKE to “climb” the driver’s seat. If the vehicle has a rubber-ized floor mat, remove it when towing.

Note: if the towed vehicle has a steering wheel tilt latch, it may be easier to position AddaBRAKE with the steering wheel tilted up.

Seat and/or pedal positioning systems may affect the towed vehicle braking system.

CAUTION — for Saturn Vue and other vehicles —If the towed vehicle’s engine must be started periodically…

Always deplete the vacuum in the vehicle’s power brake system BEFORE YOU RESUME TOWING. If the vacuum is not released, AddaBRAKE will apply excessive force when it is activated, which will cause severe tire and/or brake system damage to the towed vehicle. Refer to the caution statement on pages 19 and 20 for further information.

Figure 5

12

Attach the pedal clampcontinued from preceding page

7. Pullthehairpinclip(Figure6)out,thenlifttheslot-tedarm(Figure6)upandoutoftheway.

8. Verifythatthepedalclampisrightsideup,asshownin Figure 6 — the arrow on the stickerwill point “Up”whenthepedalclampisproperlypositioned.

9. Then,holdtheclevis(Figure7)andpullbackonthespring post (Figure 7), until the tabs under the pedalclamparewideenoughtoclearthebrakepedal.

10. Fit thepedalclampontothebrakepedal,sothatall four tabs are hooked around it (Figure 8). Then,releasethespringpost.

Note: on the initial fitting, 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.

For every subsequent vehicle, inspect the pedal clamp on the initial fitting. Verify that all four tabs are hooked around and under the brake pedal. If necessary, bend the tabs to fit, as described above.

Make certain that all four tabs on the pedal clamp are securely hooked around the brake pedal. If the tabs are loose, the pedal clamp can rotate out of position and hold the brake pedal down, even when AddaBRAKE is not activated, which will cause brake damage or other consequential, non-warranty dam-age.

11. Swingtheslottedarmbackoverthespringpost,fitthespringpost throughoneof theslots,andreattachthehairpinclip(Figure8).

Note: the spring post may be bent slightly with a pair of pliers, if necessary, in order to fit it through one of the slots.

Step BAdjust the feet and the seat pad

1. Nowthat thepedalclampis inplace,moveAdd-aBRAKEforward,untiltheaircylindershaftisfullyre-tracted (Figure 9).Make certain that AddaBRAKE isnotdepressingthetowedvehicle’sbrakepedal.

Do not move AddaBRAKE too far forward, to the

DAY-TO-DAY OPERATION

Figure 6

Figure 7

Figure 8

13

extent that the pedal clamp is depressing the brake pedal. If the brake pedal is depressed, the brakes will be applied continuously, which will cause se-vere 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.


DAY-TO-DAY OPERATIONAdjust the feet and the seat padcontinued from preceding page

2. Ifnecessary,adjustthefeetonthebottomofAdd-aBRAKE(oneateachcorner—Figure10)upordown:withawrench, loosen the locknutat the topofeachfoot,andthenturnthemclockwiseorcounterclockwise.Makecertainthatallfourfeetaremakingcontactwiththe floor of the vehicle, and that AddaBRAKE is sta-tionary — it should not rock back and forth. (In somevehicles, itmaybenecessarytoremoveoneormoreofthefeet,oritmaybenecessarytoaddoneormoreoptionalfootextensions—seethe“OptionalEquipment”sectioninthismanual.)

3. With awrench, tighten the lock nut at the top of eachfootextension(Figure10).

Unless the lock nuts are tightened with a wrench, the feet may vibrate loose during towing, and Add-aBRAKE may shift from the installed position. Un-less AddaBRAKE is properly positioned, it will not function at full capacity — the pedal clamp will not apply the proper braking pressure against the brake pedal.

4. Findabracingpointonthefrontofthedriver’sseatfor the adjustable seat pad — the seat pad stabilizesAddaBRAKE, keeping it down as it presses againstthebrakepedal.Pressthefrontoftheseattofindthefirmestpointfortheseatpad.

Figure 10

Note: do not brace the adjustable seat pad against plastic trim. The plastic will crack when AddaBRAKE is activated.

Nowthatyouhaveselectedabracingpointfortheadjustableseatpad, loosentheadjustmentknob(see“Components,”pagetwo)atthebackoftheseatpad,andmovetheseatpadupordownuntilthetopoftheseatpadmatchestheheightofthebracingpoint.

Note: the seat pad may be rotated 180 degrees or removed entirely for a better fit. There are also two anchor holes that the adjustment knob on the seat pad may be threaded into, for additional fit options.

Oncetheheightisadjusted,tightentheadjustmentknobontheseatpad.

5. Next, slide the driver’s seat forward, until it justtouchestheadjustableseatpad.Ifnecessary,allowasmallgap,ratherthanallowingAddaBRAKEtodepressthebrakepedal.MakecertainthatAddaBRAKEisnotdepressingthetowedvehicle’sbrakepedal.

The driver’s seat must not be too far forward, to the extent that the AddaBRAKE pedal clamp is depressing the towed vehicle’s brake pedal. If the brake pedal is depressed, the brakes will be applied continuously, 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.

Step CPlug in the power cord

Check the 12-volt outlet socket before plugging in the AddaBRAKE 12-volt power cord, to make cer-tain that the socket has been wired correctly. The contact point at the bottom of the socket should be positive, and the outer shell around the top of the socket should be negative. If the positive and negative connections have been reversed, the fuse in the AddaBRAKE power cord will blow when the cord is plugged into the 12-volt outlet.

1. Plugthe12-voltpowercordintothe12-voltoutlet,andsecureitbypressingthecordlock(Figure11)intothe12-voltoutlet.


Figure 9

14

Plug in the power cordcontinued from preceding page

Push the cord lock forward, into the 12-volt out-let, to properly secure the 12-volt power cord. If the cord lock is not over the 12-volt outlet, the power cord may vibrate loose, causing a loss of power or an intermittent power supply. AddaBRAKE will not function without a continuous power supply.

2. Now,theredlightonthe12-voltpowercordshouldilluminate.(OneofthefourLEDsunderthe“Pressure”buttonwillalsoilluminate,toindicatethecurrentbrakepressuresetting.Youwilladjust thissetting inStepE—“Setthebrakepressure.”)

Iftheredlightonthe12-voltpowercorddoesnotilluminate,thereisnopower.

Somevehiclesonlyhavepowerattheoutletwhenthe engine is running. If there is no power, you caninstallROADMASTER’soptional12-voltoutletkit(partnumber9332).Wheninstalled,thisoutletkitwillprovidepowerevenwhentheengineisoff.

3. When thepowercord isplugged in, theaircom-pressorwillrununtil theairreservoir isfilled.Waitfortheairreservoirtofillbeforepressingthe“Test”button(StepD,next).

Step DTest and adjust positioning;

deplete the vacuum in the power brakes Beforetowing,alwayspressthe“Test”buttondown,thenreleaseit—AddaBRAKEwillcyclethepedalclampupanddownthreetimes.

This test cycle is necessary for two reasons: 1) toensurethatAddaBRAKEispositionedcorrectly;and2)to deplete any stored vacuum in the towed vehicle’spowerbrakesystem.

Always deplete the stored vacuum in the towed vehicle’s power brake system before towing — press the “Test” button down, then release it, to cycle the pedal clamp up and down three times. Depending on the make and model of the towed vehicle, it may be necessary to repeat the test cycle a second time. If the vacuum is not released, AddaBRAKE will apply excessive braking force when it is activated, which will cause severe tire and/or brake system damage to the towed vehicle.


Figure 11

1. Pressdownonthe“Test”button(Figure12),thenrelease it.AddaBRAKEwill cycle thepedal clampupanddownthreetimes.

IfAddaBRAKEmovesexcessively,orinterfereswithseat position controls, adjust its position. Check theadjustableseatpadandreadjustit, ifnecessary.

If the adjustable seat pad is not properly posi-tioned, AddaBRAKE can “climb” up the driver’s seat — the rear of the box will rise up off the floor. Unless AddaBRAKE is properly positioned, it will not function at full capacity — the pedal clamp will not apply the proper braking pressure against the brake pedal. Check the adjustable seat pad after the pedal clamp has cycled during a test. If the rear of the box has “climbed” the driver’s seat, readjust the seat pad so that AddaBRAKE cannot “climb.”

15

Figure 12

Step ESet the brake pressure

The brake pressure setting is the amount of forceAddaBRAKEwillapply to the towedvehicle’sbrakes.Thesettingisbasedonweight—theweightofthetowedvehicle,plustheweightofall itscontents.

Note: 1999 and newer Jeep Grand Cherokees are set to 45 psi, regardless of the weight.

Refer to the“BrakePressureChart” (below) to findthemaximumbrakepressuresetting foryourvehicle.Initially, set brake pressure near (but not above) themaximumrecommendedvalue.

Thedegree towhich thissettingwillaffect themo-torhomewillvary,dependingonthesizeandweightofthemotorhome in comparison to the size andweightof the towed vehicle. A sharp pull at themotorhomemay indicate that the brake pressure is set too high.Or,evenifthepressureissetcorrectly,youmayprefertolowerthesettinguntilthetowedvehiclebrakeswithlessforce.

Do not set brake pressure above the maximum recommended value. If brake pressure is set above the maximum, AddaBRAKE will apply excessive force to the towed vehicle’s brake pedal, which will cause tire and/or brake system damage, as well as other consequential, non-warranty damage. Conversely, do not lower the brake pressure set-ting to the point that it negates the benefit of the supplemental braking system. Insufficient brake pressure will lengthen stopping distance, and may also cause a loss of vehicular control. Failure to follow these instructions may cause property damage, personal injury or even death.

1. Pulloutontheregulatorcontrolknob(Figure13)to


Brake Pressure ChartWeightof Maximumtowedvehicle recommendedandall itscontents pressuresetting

1,500-2,000pounds ................................... 25psi2,000-2,500pounds ................................... 35psi2,500-3,000pounds ................................... 35psi3,000-3,500pounds ................................... 40psi3,500-4,000pounds ................................... 45psi4,000-4,500pounds ................................... 50psi4,500-5,000pounds ................................... 55psiover5,000pounds ..................................... 60psi

For Jeep Grand Cherokee… Maximum recommendedTowedvehicle pressuresetting

JeepGrandCherokee ............................... 45psi(1999andnewer)

unlockit.

2. Then,pressandholdthe“Test”buttondown(Figure13).Iftheairreservoirisnotcompletelyfilled,waitfortheaircompressortofill thereservoir.

3. Next,turntheregulatorcontrolknobclockwisetoincrease thebrakingpressure,orcounterclockwise todecreasethebrakingpressure.

4. Whentheneedleonthepressuregaugematchesthepressuresettingyouhavechosen,releasethe“Test”button.Then,pushtheregulatorcontrolknobdowntolockit inplace.

Itisonlynecessarytosetthebrakingpressureonce— after the pressure has been set, AddaBRAKEwillalwaysbrakewiththesameforce.

5. Tocheck thebrakepressure,pressandhold the“Test” button down. As the pedal clamp extends, theneedleonthegaugewillpointtotheselectedpressuresetting.

Step FConnect the wiring harness;test the break away system

1. Connect the AddaBRAKEwiring harness to thebreakawaywiringharness(two-prongconnectors)andthebrakesignalwire(bulletconnectors).

2. Atthetowedvehicle,clipthesteelbreakawayca-ble(Figure1) to the largeringonthebreakawaypin(Figure 1), then clip the other end of the steel breakawaycabletotherearofthemotorhome,closetothecenter.


Figure 13

16

DAY-TO-DAY OPERATIONConnect the wiring harness;test the break away systemcontinued from preceding page

3. Periodically,testthebreakawaysystem—pullthebreakawaypinoutofthebreakawayswitch.TheAdd-aBRAKEpedalclampwillextendwhenthepinispulled.Insert the pin back into the switch. TheAddaBRAKEpedalclampwillretract.

When connecting the break away system, always check the following:• Connectthecableattherearofthemotorhome,close to the center. Connecting the cable toward either side of the motorhome may cause the break away pin to be pulled when the motorhome turns, activating the break away system. • Becertaintherearenoobstructionswhichwouldprevent the cable from pulling freely away from the break away switch. Do not wrap the cable around anything — doing so could keep the cable from pull-ing the break away pin, preventing the system from activating in a break away.• Makesurethecableisthecorrectlength… • The cable must be long enough to prevent

the break away pin from being pulled out during normal towing — make certain there is enough slack to allow for sharp turns. If the cable is not long enough, the break away

system will activate even though the towed vehicle has not detached.

• Thebreakawaycablemustbelongerthanthesafety cables. This will prevent the break away system from activating if a component of the towing system has separated, but the towed vehicle is still held by the safety cables.

• Make certain that the cable is not too long —it should not hang down to the extent that it may catch on obstructions, or drag on the ground. This much slack could allow the cable to be pulled inadvertently, activating the break away system.

• Ifyouhaveatelescopingtowbar,allowenoughslack for the tow bar arms to be fully extend-ed.

• Leave the break away pin in place, evenwhenthe vehicle is not being towed. If the pin is not in place when AddaBRAKE is connected, the break away system will be activated — the air cylinder will extend and will not retract. Failure to follow these instructions may cause property damage, personal injury or even death.

Step GConnect the motorhome

monitor patch cord Note: if both ends of the monitor wiring harness were connected to open terminals on the electrical sockets, the motorhome monitor patch cord is unnecessary. Re-fer to Steps C and F under “Initial Installation.”

1. Atthetowedvehicle,connectamalebulletconnec-toronthepatchcordtothefemalebulletconnectoronthemotorhomemonitorwiringharness.

At thebackof themotorhome,connect theothermalebulletconnectoronthepatchcordtothefemaleconnectoronthemotorhomemonitorwiringharness.

Allowenoughslacktopreventthepatchcordfrombeing pulled loosewhen themotorhome turns. If thecord is too long,wrap itaround the towedvehicle-to-motorhomeelectricalcord.

Step HTest the braking system

Note: the motorhome and towed vehicle must be stationary for the system test, and ready for towing — all components of the braking system must be properly connected and receiving power. Then, according to the manufacturer, make all adjustments necessary to pre-pare 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.

Refer to the owner’s manual, or call the dealership or the manufacturer for vehicle-specific information.

1.Confirmtheproperoperationofthesupplementalbraking system: depress and hold themotorhome’sbrakepedaldown.TheAddaBRAKEaircylindershaftand pedal clampwill extend (after approximately twoseconds).Then,releasethebrakepedal.Atthetowedvehicle, theAddaBRAKEair cylinder shaft andpedalclampwillretract.

2. Confirmthatthemotorhomemonitorisfunctioning:theLEDwillilluminateafterthemotorhome’sbrakeped-alisdepressed(afterapproximatelytwoseconds),andstopilluminatingwhenthebrakepedalisreleased.

If the LED does not illuminate… …at any time when the motorhome brake pedal is depressed, it may indicate that AddaBRAKE is not functioning. If AddaBRAKE is not functioning,


17

Responding to an audio alert If, for any reason, AddaBRAKE is depressing thetowedvehicle’sbrakepedal continuously forapproxi-mately20seconds,themotorhomemonitorwillsignalyouwithanaudioalert.

In addition to the audio alert, themonitor LEDwillbeilluminatedcontinuously.

Stopimmediatelyafteranaudioalertfromthemoni-tor.TheaudioalertandilluminatedLEDareindicatingthatthetowedvehicle’sbrakepedalisbeingdepressed.Significantbrakesystemdamagetothetowedvehicle,aswellasotherconsequentialdamage,mayresult.

Identifyandcorrectthecauseoftheaudioalertbe-foreusingAddaBRAKE.

If the monitor signals you with an audio alert, stop immediately. Identify and correct the cause of the audio alert before using AddaBRAKE. Failure to respond to an audio alert, as indicated above, may cause property damage, personal injury or even death.

PROTECTION MODES

Extended braking protection Toprotectthetowedvehicle’sbrakes,AddaBRAKE willautomaticallyreleasebrakingpressureafteranex-tendedperiodofcontinuousbraking.

Toregainsupplementalbrakinginthetowedvehicle,releaseanddepressthemotorhome’sbrakepedal.

Note: activating the exhaust brakes in some motor-homes may also illuminate the motorhome brake lights. If this is the case, AddaBRAKE will be activated with the exhaust brakes, and will automatically release braking pressure after an extended period of continuous brak-ing.

To regain supplemental braking in the towed vehicle, and use an exhaust brake system of this type, cycle the exhaust brakes on and off.

AddaBRAKE has two built-in safeguards to protect the towed vehicle’s brakes. These protectionmodes are describedbelow.

DAY-TO-DAY OPERATIONTest the braking systemcontinued from preceding page

it will not brake the towed vehicle in tandem with the motorhome, which will lengthen stopping distance, and may also cause a loss of vehicular control. Refer to the ‘Troubleshooting’ section (under ‘Electrical’) to identify and correct the cause of the malfunction, then test to ensure that the LED and AddaBRAKE are both operating properly. Failure to follow these instructions may cause property damage, personal injury or even death.

3. Confirmtheproperoperationoftheextendedbrak-ingmode: depress and hold themotorhome’s brakepedal down. TheAddaBRAKE air cylinder shaft andpedal clampwill extend. After approximately 15 sec-onds, the air cylinder shaft and pedal clampwill re-tract.

4. Attheinitialinstallation,andperiodicallythereafter,confirmtheproperoperationoftheaudioalert:depress

andhold the towedvehicle’sbrakepedaldown.Afterapproximately20seconds,themotorhomemonitorwillactivatetheaudioalert.(Tocanceltheaudioalert,re-leasethetowedvehicle’sbrakepedal.)

5. Attheinitialinstallation,andperiodicallythereafter,confirmthatthemotorhometurnsignalsdonotactivateAddaBRAKE.

An incorrect flasher speed may activate Adda-BRAKE unnecessarily, causing excessive brake wear or other consequential, non-warranty damage. If the turn signals activate AddaBRAKE, check the turn signal flasher rating — it may be inadequate for the motorhome-towed vehicle combination. If this is the case, replace the flasher with one rated at or above the number of bulbs in the motorhome-towed vehicle combination.

18

QUICK REFERENCE CHECKLIST

If the vacuum is not released, AddaBRAKE will apply excessive braking force when it is activated, which will cause severe tire and/or brake system damage to the towed vehicle.

9. Connect the AddaBRAKEwiring harness to thebreakawaywiringharnessandthebrakesignalwire.

10. Connect thebreakawaycable to the frontof thetowedvehicleandtotherearofthemotorhome.Peri-odically,testthebreakawaysystem.

11. Connectthemonitorpatchcordtothefrontofthevehicleandtotherearofthemotorhome.

Note: this step is unnecessary if the monitor wiring was connected to the electrical sockets in the towed vehicle and the motorhome. Refer to Steps C and F under “Initial Installation.”

12. Test toconfirm theproperoperationof thepedalclamp,themotorhomemonitorLED,andtheextendedbrakingprotectionmode.(Periodically,confirmtheprop-eroperationofthemonitoraudioalert,andthatthemo-torhometurnsignalsdonotactivateAddaBRAKE.)

13. Makecertain that the towedvehicle’semergencybrakeisreleased.

Failure to release the towed vehicle’s emergency brake before towing will result in severe tire and brake damage, or a brake system fire, or other con-sequential damage. Damage caused by towing a vehicle with its emergency brake on is not covered under warranty. Failure to follow these instructions may cause property damage, personal injury or even death.

AddaBRAKE is designed to work with a ‘dead’ brake pedal. Do not leave the vehicle’s engine running while towing, as this will allow the power brakes to function. The power brakes will cause excessive braking in the towed vehicle, resulting in non-warranty brake system and tire damage. Dis-connect AddaBRAKE if, for any reason, you must tow with the engine running.

If the towed vehicle’s engine must be started pe-riodically (according to the manufacturer’s instruc-


Once the other components of your supplementary braking system have been installed, follow the steps belowtoconnectAddaBRAKEtothetowedvehicle;seethenextpagetodisconnectAddaBRAKE.Formore

detailedinformation,refertotheappropriatesectionunder“Day-to-dayoperation.”

Connecting AddaBRAKE 1. Slidethedriver’sseatback,asfarasitwillgo.

2. PositionAddaBRAKEbetweenthedriver’sseatandthebrakepedal,at theapproximateposition itwill sitwhenconnectedtothebrakepedal.

3. Presstheairreliefbutton(Figure5)tomakecertainthatallof theair in theAddaBRAKEair reservoirhasbeenreleased.

4. Attachthepedalclamptothebrakepedal.

5. MoveAddaBRAKE forward, until the air cylindershaft(Figure9)isfullyretracted.

6. Slidethedriver’sseatforward,untilitjusttouchestheAddaBRAKEadjustableseatpad.Ifnecessary,al-lowasmallgap, rather thanallowingAddaBRAKE todepressthebrakepedal.

The driver’s seat must not be too far forward, to the extent that the AddaBRAKE pedal clamp is depressing the towed vehicle’s brake pedal. If the brake pedal is depressed, the brakes will be applied continuously, 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.

7. Plug in the 12-volt power cord, and secure it bypressingthecordlock(Figure11)intothe12-voltout-let.

Whenthepowercordispluggedin,theaircompres-sorwillrununtiltheairreservoir isfilled.

8. Oncetheairreservoir is filled,pressandreleasethe“Test”button(Figure12).Thepedalclampwillcycleupanddownthreetimes.

IfAddaBRAKEmovesexcessively,orinterfereswithseat position controls, adjust its position. Check theadjustableseatpadandreadjustit, ifnecessary.

Always deplete the stored vacuum in the towed vehicle’s power brake system before towing — press the “Test” button down, then release it, to cycle the pedal clamp up and down three times. Depending on the make and model of the towed vehicle, it may be necessary to repeat the test cycle a second time.

19

Charge the towed vehicle’s battery (with a battery charger or by running the engine) after towing. AddaBRAKE draws power from the towed ve-hicle’s battery. Depending on the age and condition of the battery, AddaBRAKE may drain the battery completely if it is not charged.

Connecting AddaBRAKEcontinued from preceding page

tions), and AddaBRAKE is installed, stop the mo-torhome while the towed vehicle’s engine is run-ning. Once the towed vehicle's engine is turned off, press the AddaBRAKE “Test” button down, then release it, to cycle the pedal clamp up and down three times. Depending on the make and model of the towed vehicle, it may be necessary to repeat the test cycle a second time. If the stored vacuum in the towed vehicle’s power brake system is not released in this manner, Ad-daBRAKE will apply excessive braking force when it is activated, which will cause severe tire and/or brake system damage to the towed vehicle.

Disconnecting AddaBRAKE 1. Pullonthecordlock(Figure11)toreleaseit,andunplugthe12-voltpowercord.

2. DisconnecttheAddaBRAKEwiringharnessfromthebreakawaywiringharnessandthebrakesignalwire.

3. Movethedriver’sseatback,asfarasitwillgo.

4. Pressandholdtheairreliefbutton(Figure5)untilalltheairintheairreservoirisreleased.Ifnecessary,continue to hold the air relief button andmove Ad-daBRAKE back, to allow easier access to the brakepedal.

5. Detachthepedalclampfromthebrakepedal.

6. Wrapthe12-voltpowercordandthewiringharnessaroundthecordholder,andliftAddaBRAKEoutofthevehicle. (The adjustable seat pad can be used as ahandle.)

7. Disconnectthemotorhomemonitorpatchcordfromthetowedvehicleandthemotorhome.

Note: this step is unnecessary if the monitor wiring was connected to the electrical sockets in the towed vehicle and the motorhome. Refer to Steps C and F under “Initial Installation.”

8. Disconnectthebreakawaycable(Figure1)fromthefrontofthetowedvehicleandthemotorhome.Donotre-movethelargeringandpinfromthebreakawayswitch.

Leave the break away pin in place (on the ring), even when the vehicle is not being towed. If the pin is not in place when AddaBRAKE is connected, the break away system will be activated — the air cylinder will extend and will not retract.

QUICK REFERENCE CHECKLIST

20

TROUBLESHOOTINGSymptom

AddaBRAKEdoesn’t fit properlyinthetowedvehicle.

The pedal clamp doesn’t fit thebrakepedalsecurely.

Theaircylindershaftwillnotex-tendtoconnectthepedalclamptothebrakepedal.

Thepedalclampdoesnotextendto the brake pedal, when Adda-BRAKEisproperlyinstalled.

The brake pedal clamp comesinto contact with the AddaBRAKE housing.

The towedvehicle’sseatmovesafter AddaBRAKE depresses thebrakepedal.

AddaBRAKE “climbs” up theseat.

After towing, there is excessivebrake dust on the wheels of thetowed vehicle, and/or an unusu-al odor near the towed vehicle’sbrakes.

Question

How do I increase or decreasebrakingpower?

Symptom

ThefirsttimeAddaBRAKEisac-tivated, the towed vehicle brakeswith excessive force, ‘flat-spotting’thetires.

Solution

Positioning Useoneormore footextensions toelevateAddaBRAKEoverobstruc-tionssuchasductwork,adoorjamboracenterconsolethatjutsintotheavailablespace.(Refertothe“OptionalEquipment”section.)

Useapairofplierstobendthetabsof thepedalclampforabetter fit.Ifthepedalclampstilldoesn’tfit,contactROADMASTER.

Theairreservoir isfull.Releasetheairbypressingtheairreliefbutton(Figure5).

Useanoptionalair cylindershaftextension toextend the reachof theaircylindershaft.(Refertothe“OptionalEquipment”section.)

Brake pedals that are somewhat horizontal cause the pedal clamp totilt,andtointerferewiththeAddaBRAKEhousingwhenitretracts.Useanoptionalaircylindershaftextensiontogainadditionalclearance.(Refertothe“OptionalEquipment”section.)

Readjust the seat and/or the adjustable seat pad.Refer to StepB in“Day-to-dayoperation”—“Adjustthefeetandtheseatpad.” Afteradjusting theseat,press the“Test”button(Figure12)down, thenrelease it, to cycle thepedal clampupanddown three times.Watch theseatastheaircylindershaftextendsandretracts—ifitstillmoves,adjusttheseatasecondtime,andrepeatthetestcycle.

• If there is a rubberized floormat underAddaBRAKE, remove it duringtowing.• Check thepositionof theadjustableseatpad.Theseatpadservesasananchorpoint,tokeepAddaBRAKEdownasitpressesthebrakepedal.Adjusttheseatpadupordown,ifnecessary.

Brake pressure setting Readjust the braking pressure to a lower setting. Refer to Step E in“Day-to-dayoperation”—“Setthebrakepressure.”

Answer

Readjustthebrakingpressuretoahigherorlowersetting.RefertoStepEin“Day-to-dayoperation”—“Setthebrakepressure.”

Solution

Installed in vehicle with ‘active’ brakes Thevehiclemayhavean ‘active’ brakingsystem.Refer to thecautionstatementonpageoneforinformation.

21

TROUBLESHOOTINGSymptom

The fuse for the towedvehicle’s 12-volt outletkeepsblowing.

The compressor comeson when AddaBRAKE ispluggedin,butnotactuallybeingusedforbraking.

Nothing happens afterproperinstallation.

ThemotorhomemonitorLED does not illuminate,even though thebrakes inthetowedvehiclearebeingapplied.

AddaBRAKE doesn'tstop braking when themotorhome brakes are re-leased.Itkeepsbrakingforabout15seconds.

Solution

Electrical Checkthe12-voltoutlet fusesize. Itmustberatedat15ampsorhigher. If thetowedvehicle’sfuseisnotsufficient,installtheoptional12-voltoutletkit(partnumber9332;refertothe“OptionalEquipment”section).

AddaBRAKE’scompressormayactivateaboutevery10minutesduetonormalairdissipation.Ifthecompressoractivatesrepeatedlywithin10minutesorless(whennotbraking),contactROADMASTER—youmayhaveanair leakinAddaBRAKE.

• AddaBRAKEwillactivatewithintwosecondsafterthemotorhomebrakepedalhasbeendepressed.Hold themotorhomebrakepedaldownforat least twoseconds;checktoseeifAddaBRAKEactivates.• VerifythatAddaBRAKEisreceivingabrakelightsignalfromthemotorhome—withatestlight,checkforvoltageatthefemalebulletconnector(attheendofthegreenbrakesignalwire)whichispluggedintotheAddaBRAKEwiringharness.Ifthereisnovoltage,checkthebrakesignalwireconnectionsatthetowedvehicle’selectricalharness(Referto“Attachthebrakesignalwire”under“InitialInstallation.”).• Check the towedvehicle’sbatteryvoltage. If thebatterydoesn’thavesufficientpower,AddaBRAKEwillnotoperate.• Check for a red light at the end of the 12-volt power cord. If there is no light,thereisnopower. • Checkthefuseontheendofthe12-voltpowercord.If thefuseisblown,po-

larityat the12-voltoutletmaybecrossed,withpositiveconnectedtoground,andgroundtopositive.Correct thewiring,andreplacethefuse in the12-voltpowercord.

• An optional 12-volt outlet kitmay be required.Refer to “Before you begin theinitial installation,”inthismanual.• Theoperating temperature range isbetween -2° and +150° F (-19° to +66° C). AddaBRAKE will not operate at temperatures above or below this range.

• Hold the towedvehiclebrakepedaldown, forapproximately20seconds. If theaudioalertactivates,thenoneofthetwoconnectionstotheLEDmayhaveworkedloose.Checkboththepowerandthegroundconnections.• Makecertain that themotorhomemonitorpatchcordbetween the twovehiclesissecurelyconnected. (Or, ifyouhaveconnected themonitorwiring to the towedvehicleandmotorhomeelectricalsockets,makecertain that the towedvehicle-to-motorhomeelectricalcordissecurelyconnected.)• ThemonitorLEDisconnectedtothetowedvehicle’sbrakelightcircuit.Ifthefusein thecircuit is blown, theLEDwill not operate.Check the towedvehicle’sbrakelights—iftheyilluminatewhenthebrakepedalisdepressed,thefuseisgood.• Verify that there isanelectricalgroundbetween themotorhomeand the towedvehicle.• DidyouinstalltheoptionalBrake-LiteRelay?Ifso,makecertainthatthemonitorwireisconnectedtothetowedvehicle’sbrakelightwireafterthebrakelightswitch,butbefore theBrake-LiteRelay—connecting thewireanywhereelsewillpreventthemonitorLEDfromfunctioning.

Ifthetowedvehiclehasbeenwiredfortowing(asopposedtoinstallingataillightwiringkit ormagnetic tow lights),diodesmustbeattached to thewires. If diodesarenotattached,electricalfeedbackthroughthebrakelightwirewillpreventAdd-aBRAKEfromreleasingbrakingpressureuntiltheextendedbrakingprotectionmodeoverridesthebrakelightsignal,afterapproximately15seconds. Refer to step 10 under “Before you begin the initial installation” for additionalinformation.

22

FORD ‘NEUTRAL TOW’ VEHICLES

5. Testtoverifythatthediodehasbeenproperlyin-stalled—thetowedvehicle’sbrakelightswillilluminatewhenthebrakepedalispressed.

To wire the vehicle for towing… Thereare threemethodsavailablewhichwillallowatowedvehicle’sturnsignals,brakelightsandrunninglights towork inconjunctionwith themotorhome’s:1)installataillightwiringkit(alsocalleda‘bulbandsocketkit,’ part number 155); 2) installmagnetic tow lights(part number 2100 or 2120); or 3) wire the vehicle’sturnsignals,taillightsandbrakelightsfortowing. Instructionsforthethirdmethodarebelow;instruc-tionsforthefirsttwomethodsareincludedwiththekits. 1. Afteryouhaveinstalledadiodedownstreamfromthe brake light switch (Figure 14), wire the vehicle’sturn signals, taillights and brake lights for towing byinstallingsixdiodes. Beforeinstallingthediodes,verifythatthetowedvehiclehasseparatebrakeandturnsignals—oneachside, there are amber or red turn signal lightswhichareseparatefromthebrakelights(Figure2). Note: if the motorhome has combined brake and turn signals, use Figure 15 to wire the towed vehicle. If the motorhome has separate brake and turn signals, visit www.roadmasterinc.com. Use the ‘Separate towed vehicle to ‘separate’ motorhome’ wiring diagram, under ‘Support.’ Note: if a 3-to-2 converter has been installed in a motorhome with separate brake and turn signals, wire the towed vehicle according to Figure 15. To test for a 3-to-2 converter, use a test light to find the turn signal and brake light circuits on the motorhome electrical socket. If the same circuit energizes both the turn signals and the brake lights, a 3-to-2 converter has been installed. If the turn signal and brake lights have separate circuits, a 3-to-2 converter has not been


To wire the vehiclefor supplemental braking…

If AddaBRAKE is to be installed in any Ford vehicle with a ‘neutral tow’ kit, do not install a Brake-Lite Relay. Using a Brake-Lite Relay in these vehicles may prevent disengagement of the trans-mission for towing, causing severe damage to the transmission. Install a diode, rather than a Brake-Lite Relay, according to the instructions below.

1. Locatethetowedvehicle’sbrakelightswitchand,withatest light, findthe“cold”sideof thebrake lightswitch—the“cold”sideoftheswitchdoesnotregistervoltageunless thebrakesareapplied.Witha12-voltmeter,verifythatyouhavefound12VDC+. Then,removethebrake light fuse, located in thevehicle’sfusepanel.

Failure to remove the brake light fuse from the vehicle’s fuse panel may activate the vehicle’s theft deterrent system, or other electrical system indi-cators, if the brake pedal is pressed during the installation. This may require non-warranty repair to the vehicle.

2. Next,cutthebrakelightwire,afewinchesdown-streamfromthe“cold”sideofthebrakelightswitch. 3. Installthediodeinline,asshowninFigure14. Mountthediodeunderthedashboard,afewinchesawayfromthebrakelightswitch. 4. Reinstallthebrakelightfuse,whichyouremovedinstep1.

SomeFordvehicles,suchastheFordExplorer,areequippedwitha‘neutraltow’kit.Usetheinstructionsbelowtowirethesevehiclesforsupplementalbraking,andfortowing.

Figure 14

23

To wire the vehicle for towing…continued from preceding page

installed. 2. First,cutthefactoryturnsignal,taillightandbrakelightwires,asclosetothelightsaspossible. 3. Next,installthesixdiodesinline,asclosetothelightsaspossible.

Attach the diodes as close to the vehicle’s lights as possible, to avoid interaction with other circuits which may be tied into the center brake light, the running lights, the turn signals or the brake light wires. Attaching the diodes further away may cause the towed vehicle’s lights to work improperly, and may also cause damage to other electrical compo-nents in the vehicle.

4. Oneachside,jumpthebrakeandturnsignaldiodes,asshowninFigure15.

Unless the brake and turn signal diodes are jump-

FORD ‘NEUTRAL TOW’ VEHICLESed, the towed vehicle’s brake light circuits will ‘override’ the motorhome’s turn signals — the towed vehicle’s turn signals will not operate in conjunc-tion with the motorhome’s turn signals, as required by law.

5. Test toverify that thediodeshavebeenproperlyinstalled… A. Ifthemotorhomehasa‘combined’lightingsys-tem… 1. Thetowedvehicle’sturnsignalsandbrakelightswillbothflash(eachside)whenthemotorhome’sturnsignal ison;and 2. Whenthemotorhome’sturnsignalandbrakesignal are both on (each side), the towed vehicle’sbrake lightswillstay illuminated,while theturnsignalflashes. B. Ifthemotorhomehasa‘separate’lightingsys-tem, the towedvehicle’s turnsignalsandbrake lightswill illuminateidenticallytothemotorhome’s.

Figure 15

24

OPTIONAL EQUIPMENT

12-volt extension cord(partnumber9331) This extension cordwill extend your 12-volt outletbysixfeet.

12-volt outlet kit(partnumber9332) AddaBRAKE ispowered through the12-voltoutlet,withtheignitionkeyturnedtothe“tow”position.Ifyourvehiclehasnopowertotheoutletwiththekeyinthisposition,usethiskit.

1½" air cylinder shaft extension (partnumber9336) Thisoptionextendsthereachoftheaircylindershaftby1½inches.Itthreadsbetweenthepedalclampandthecylindershaft.

Air cylinder shaft and foot extensions

AlthoughAddaBRAKEfitsmostvehiclesasis,withnomodificationsneeded,itmaybenecessarytogainadditionalclearanceoverobstructionsonthe floor,or toextend the reachofAddaBRAKEtoensureasecureandstablefit. Theaircylindershaftextensions increase thereach of AddaBRAKE.Use an air cylinder shaftextensionifthedistancebetweenthedriver’sseatandthebrakepedalistoofartomaintainasecureanchorpointbetweentheseatandtheadjustableseatpad. Use one ormore foot extensions to elevateAddaBRAKEoverobstructionssuchasductwork,adoorjamboracenterconsolethatjutsintotheavailablespace.

3½" air cylinder shaft extension (partnumber9336-3) Thisoptionextendsthereachoftheaircylindershaftby3½inches.Itthreadsbetweenthepedalclampandthecylindershaft.

Foot extensions (oneextension:partnumber9337fourextensions:partnumber9337-4) ThisoptionallowsAddaBRAKEtosituptooneinchhigher in thevehicle.Unscrew the includedfoot,screwtheextension in,and thenscrewtheoriginalfootintotheextension.

12-volt ‘Y’ adaptor (partnumber9330) Usethis‘Y’adaptortoconnectmorethanone12-voltaccessorytoasingle12-voltoutlet.

Second vehicle kit (partnumber98800) IfyouswitchAdda-BRAKEbetweentwovehicles, installthisbreakawaysystem,andmonitorandbrakelightsignalwiring(notpictured)inthesecondvehicle.

Brake-Lite Relay(partnumber88400) TheBrake-LiteRelayallowsthetowedvehicle’sturnsignalsandbrakelightstoworksimulta-neously, inconjunctionwiththeexistingtowedvehicle-to-motorhomeelectricalconnection.

25

1.WARRANTY 1a.WARRANTY OF CONFORMITY AT TIME OF SALE ROADMASTER, Inc.warrants that at the time of saleof thisproduct itwillbe freefromdefects inmaterialandmanufactureandwillconformtoROADMASTER’Sspeci-ficationsfortheproduct. 1b.CONDITIONAL ONE-YEAR WARRANTY Inadditiontotheprecedingtime-of-salewarranty,iftheproductregistrationcardiscompletelyandaccuratelyfilledoutandmailedtoROADMASTERwithinthirty(30)daysofpurchase,ROADMASTERwillprovideanadditionalwar-rantythatforaperiodofoneyearaftersaletheproductwillremainingoodworkingorder,PROVIDEDTHATtheprod-uctisinstalledandmaintainedinaccordancewithROAD-MASTER’Sinstructionsandisnotsubjectedto:(a)altera-tionorunauthorizedrepairsorrepairsbyanyoneotherthanROADMASTER or aROADMASTER-authorized servicecenter, (b)misuse, abuse, commercial use, or impropermaintenance,(c)ActsofGod(includingwithout limitationhurricanes,tornadoes,floods,orothersevereweatherornaturalphenomena),(d)failuresduetoproductsnotsup-pliedbyROADMASTER,or(e)othertreatments,uses,orinstallationsforwhichtheproductwasnotintended.Thiswarrantyextendsonlytothefirstretailpurchaser-consumeroftheproductandisnottransferable. EXTENDED WARRANTY PERIOD:IfROADMASTERreceives the product registration card, completely andaccurately filled out, within thirty (30) days of purchase,ROADMASTERwillenlargetheone-yearwarrantyperiodintheprecedingparagraphtoaperiodoftwoyears.

2.DISCLAIMER OF OTHER WARRANTIES The precedingwarranties are the exclusive and soleexpresswarranties given byROADMASTER. They su-persedeanyprior,contraryoradditional representations,whetheroralorwritten. Noagent, representative,dealeroremployeehastheauthoritytoalterorincreasetheob-ligationsor limitationsof thiswarranty. Any impliedwar-ranties,includingtheWARRANTYOFMERCHANTABILITYandanyWARRANTYOFFITNESSFORAPARTICULARPURPOSE, are limited in duration to thirty days or thetermof theapplicableexpresswarranty providedabove,whicheverislonger. Some states do not allow limitations on how long animpliedwarranty lasts, so the above limitationmay notapplytoyou.

3.EXCLUSIVE REMEDY FOR ANY NONCONFORMITIES If during the applicableWarranty Period, the productdoes not conform to the preceding Warranties, notifyROADMASTERasprovidedbelow, andwithin a reason-abletimeROADMASTERwillprovide,atitsoption,oneofthe following: (1) replacement components for anynon-conformingordefectiveproductorcomponentsor(2)thepercentage of the purchase price for the nonconformingproduct equal to the percentage of theWarranty PeriodremainingwhenROADMASTERisnotifiedofthenoncon-formity.ROADMASTERwill,atitsoption,(a)usenewand/orreconditionedparts inperformingwarrantyrepairsandmaking replacement products, (b) use parts or productsof original or improved design in the repair or replace-ment.IfROADMASTERrepairsorreplacesaproduct,its

warrantycontinuesfortheremainingportionoftheoriginalWarranty Period or 60 days from the date of the returnshipmenttothecustomer,whicheverisgreater.Allreplacedproducts and all parts removed from repaired productsbecomethepropertyofROADMASTER.ROADMASTERwill not provide, andwill not be liable for, labor, costsofremovalorreinstallationofcomponents,disposal,shipping,freight,taxes,orotherincidentalcharges.

THESE REMEDIES ARE THE EXCLUSIVE AND SOLE REMEDIES FOR ANY BREACH OF WARRANTY. Foranybreachofwarranty,theOwnermusttelephoneROADMASTERat1-800-669-9690withinthirty(30)daysafter discovering the nonconformity. Do not return anyproduct without first callingROADMASTER and gettinga return authorization number. Returned productsmustincludethereturnauthorizationnumberandacopyoftheoriginalinvoice,billorotherproofofthedateofpurchase.Thedateofpurchasemustcoincidewiththeoriginalwar-ranty registration card on file. ROADMASTERwill au-thorize (a) shipmentof theproduct toROADMASTERor(b) repairor replacementat thenearestwarrantyservicecenter—inbothcaseswithshippingatyourexpense. Donotpurchasereplacementpartsorpayforrepairlabor—youwillnotbereimbursed.Compliancewiththerequirementsof this paragraph is a condition to coverage under theWarranty: if these requirements are not compliedwith,ROADMASTERwillhavenoobligationtoprovideanyrem-edyforanybreachofwarranty.

4.DISCLAIMER OF INCIDENTAL AND CONSEQUENTIAL DAMAGES INNOEVENTSHALLROADMASTERBELIABLEFORANY INCIDENTAL, SPECIAL, INDIRECT OR CONSE-QUENTIALDAMAGES,WHETHERRESULTINGFROMNONDELIVERYOR FROMTHEUSE,MISUSEOR IN-ABILITYTOUSETHEPRODUCTORFROMDEFECTSINTHEPRODUCT. Somestatesdonotallowtheexclusionor limitationofincidentalorconsequentialdamages,sotheabovelimita-tionmaynotapplytoyou.

5.APPLICABLE LAW ThisWarrantywill be interpreted, construed, and en-forced in all respects in accordancewith the lawsof theStateofWashington,withoutreferencetoitschoiceoflawrules.TheU.N.ConventiononContractsfortheInterna-tionalSaleofGoodswillnotapplytothisWarranty.

6.SEVERABILITY Ifanyprovisionofthiswarrantyisfoundtobeinvalidorunenforceable,thentheremaindershallhavefullforceandeffect,andtheinvalidprovisionshallbepartiallyenforcedtothemaximumextentpermittedbylawtoeffectuatethepurposeoftheagreement.

7.ADDRESS FOR NOTICES TO ROADMASTER ROADMASTER, Inc., 6110NE127thAve,Vancouver,WA98682 Thiswarrantygivesyouspecificlegalrights,andyoumayalsohaveotherrightswhichvaryfromStatetoState.

LIMITED WARRANTY

26

INDEX12-voltoutletkit(partnumber9332) Description ........................................................... 25 Whentoinstall .................................................4,15‘Active'brakingsystems—warningstatement ........... 1Adjustableseatpad AttachingtoAddaBRAKE .................................... 12 Fittingtotowedvehicle ........................................ 14 Cautionarystatement—positioning ..................... 15Aircylindershaft— positioningwhenconnectingAddaBRAKE .......... 13Airreliefbutton ........................................................ 12Audioalert—respondingto ..................................... 18Audiosignalcircuitboard— attachingduringinitial installation ....................... 10Batteryvoltage,charging— cautionarystatement ........................................... 20Brakelightswitch—testfor“cold”side ..................... 8Brake-LiteRelay—whentoinstall ............................. 7Brakepressure—setting ......................................... 16Brakesignalwire—initial installation .....................8-9Breakaway—definition ............................................. 6Breakawaysystem Connectingthebreakawaycable ....................... 16 Initial installation .................................................... 6 Testing ................................................................. 17Combinedbrakeandturnsignal lights—definition(Figure2) ................................... 7Cordlock—using ............................................... 14-15Depletethevacuuminthepowerbrakes ................ 15Driver’sseat—positioning whenconnectingAddaBRAKE ...................... 14,19Emergencybrake,releasing— warningstatement ............................................... 19Exhaustbrakes—cautionarynote ........................... 18Extendedbrakingprotection .................................... 18Feet—adjustingupordown .................................... 14Ford‘neutraltow'vehicles .................................. 23-24Fuses Removingfromtowedvehicle priortoinitial installation ................................... 4 Removingbrakelightfuse duringinitial installation ..................................... 8Grommet,firewall— attachingduringinitial installation ......................... 9LED,motorhomemonitor Attachingduringinitial installation ....................... 10 Properfunction ...................................................... 7 Warningstatement .................................... 11,17-18Lightingsystem,towedvehicle— modificationsto...................................................6-7Magnetictowlightsystem—wiringfor ...................... 9Patchcord—connecting .......................................... 17

Pedalclamp,attaching ....................................... 12-13Positioning—testandadjust ................................... 15Powerbrakes—releasingvacuum— cautionarystatements ...................12,15,19,19-20Powercord—pluggingin .................................... 14-15Safetydefinitions ..............................insidefrontcoverSecondvehiclekit—description .............................. 25Separatebrakeandturnsignal lights—definition(Figure2) ................................... 7Serialnumber—locationof ..............insidefrontcoverSpecifications ....................................insidefrontcoverStoplightswitchkit—whentoinstall .....................4-5Testandadjustpositioning ...................................... 15Testthebrakingsystem ........................... 10-11,17-18Turnsignals—incorrectflasher speedcaution ................................................ 11,18Vacuum,powerbrakes— cautionarystatements ...................12,15,19,19-20Wiringdiagrams ......................................................... 3

27

— advertisement —

There are several components that make up a good vehicle suspension system: shocks provide comfort; air bags support weight; anti-sway bars control left-to-right sway; trac bars reduce ‘wander;’ and steering stabilizers provide blow out protection. Use this chart to make an informed decision about what aftermarket suspension product(s) will enhance your vehicle’s stability, handling and maneuverability.

We’re the suspension expertsVery few people would say they bought their

motorhome(or truck,vanorSUV) for thesus-pension.Formostofus,thesuspensionisout

of sight andout ofmind— even though your drivingperformance,safetyandcomfortareallridingonthosecomponents. Unequal weight distribution,wornorinadequatecomponents,excessiveaxlesideplayorahigh-er center of gravity can quicklyoverpower a stock suspension,evenineverydaydriving.Unfor-tunately,findingasolutioncanbejustasfrustratingasdealingwiththeconsequences.

Do you need a custom suspension component? Every“yes”tothefollowingquestionsisa“yes”forananti-swaybar,asteeringstabilizerand/oratracbar…• Doesthevehicle“roll”whencornering?• Doesdrivingforanextendedperiodoftimeleaveyou physicallyexhausted?• Isyourrigallovertheroad—can’tkeepitbetween thelines?• Wouldyoulosecontrolifoneofthefronttiresblew out?• Doesthesteeringwheelhaveamindofitsown?• Dopassing18-wheelersandcrosswinds rock your vehiclebackandforth?• Isdrivinga‘whiteknuckle’experience?

The primary benefits of ROADMASTERsuspension components are…

• Anti-swaybars—virtuallyeliminate ‘bodyroll’ (thevehiclerollsfromsidetoside,especiallyduringcorner-ing).Anti-swaybarsstabilizethevehicle,keepingitlevel

throughcrosswindsanddramati-callyimprovingoverallhandling.• Steeringstabilizers—fronttireblow out protection. Stabilizersalso automatically compensateforoversteercausedbypotholes,ruttracksandotherunfavorableroadconditions.

• Tracbars—drasticallyreduce‘wander’(thesteeringfeelsloose,makingitdifficult—andphysicallyexhausting—tokeepthevehicleinastraightline). Eachofthesecomponentswillprotect your vehicle (improvedtirelife,reducedsuspensionwear,reducedmaintenancecostsandimprovedvehicleperformance)andprotect your family(betterdrivingcontrol,reduceddriverfatigue,morecontrolinevasivemaneuvers,andimproveddriverconfidence).

Every ROADMASTER suspension component…• …isdesignedasacustomfit,foraspecificchassis.ROADMASTERengineeringdesignstakeintoconsid-erationchassisandaxlemanufacturers’specifications(yourwarrantywillnotbeaffected).


28

for more information…Call800-669-9690,orvisitwww.roadmasterinc.com

— advertisement —

We’re the suspension expertscontinued from preceding page

Which component is right for you? ROADMASTERdesigns,engineersandmanufacturesanti-swaybars,tracbars,andsteeringstabilizersforbothoriginal equipmentmanufacturers and the aftermarket.Anti-sway bars, trac bars and steering stabilizersworkinconcertwiththeothercomponentsofyoursuspensionsystemtoaddstabilityandcontrol. Eachofthesecomponentshasaspecificroletoplay. Thegraphonthepreviouspageidentifiestheprimarybenefits of aftermarket suspensionproducts.Eachonehas value — for a specific application. It’s important tounderstandandidentifywhatyou’reexperiencing,soyoucanselectthecorrectproductsolution.

RSS Anti-Sway Bars Aremarkableimprovementinstabilityandcorneringcontrol — formotorhomes or any large vehicle,especiallytowingcombinations—isjustafewboltsaway.Anti-swaybarsfromRoadmasterSuspensionSolutionsdelivera“Wow!”differenceinRVcontrolyou’llnoticethefirsttimeyouturnthewheel.• 20 years of experienceintheRVindustry• formotorhomes, trucks, vans andSUVs • morethan60kits,eachonecustom-designed for aspecificchassisandsuspensionsystem• largediameter, cadmium-plated4140 chromoly steel bars,withheavy-dutypolyurethane bush- ings• easy installation—inmostcases,eightbolts

What do our customers say? “I noticed a difference as soon as I stepped into the motorhome — there was no rocking movement. During a recent trip we encountered substantial crosswinds. With the RSS anti-sway bar, I estimate our motorhome’s sway was reduced by 90 percent. We don’t feel anything now when a tractor trailer blows by us. I’m 100 percent satisfied — everyone should experi-ence the benefit of this product.”— Johnny Singleton, Myrtle Beach, South Carolina

A high-grAdE AllOy And A bEttEr pivOt pOint — The stock anti-sway bar (on the right) has a small diameter, 1020 grade spring steel, and a rubber bushing. The RSS anti-sway bar (to the left) has a large diameter, 4140 chromoly steel, and a polyurethane bushing, making it many times more resistant to sway.

RSS stock

Reflex Steering Stabilizers Yourbestinsuranceagainstthecatastrophiccon-sequencesofafronttireblowoutisaReflexSteer-ingStabilizer. Whenyoublowoutafronttire,yourvehiclewillmakeanabruptturntowardthattire,causingyoutoveerintooncomingtrafficorofftheroad.TheReflexSteeringStabilizer’stemperedsteelsprings,whichareattachedtothetierodsandundercarriage,auto-maticallycompensateforoversteercausedbyfronttireblowouts,potholes,ruttracksandotherunfa-vorableroadconditions,aswellascrosswindsandpassing18-wheelers. Thespringsreactinstantaneouslytobringtheve-hiclebacktocenter.

What do our customers say? “I had a Reflex Steering Stabilizer installed, and the difference was night and day — my Class C motorhome handles like a sports car. The stabilizer keeps the steering centered, no matter what the road throws at me. Ruts, bumps and hairpin curves are no problem. My steering wheel doesn’t belong to potholes any more — it belongs to me.”— Jerry Miller, Portland, Oregon

Davis TruTrac™ Bars Doesyourmotorhomevibratefromsidetoside?Are “wandering,” “rut tracking” and “lazy steering”aproblem?Tiredandfatiguedtryingtokeepinlinegoingdowntheroad? DavisTruTracbars link thechassis to the frontaxle, eliminatingexcessiveaxle sideplay,withoutaffectingnormalup-and-downsuspensiontravel. The result is precise, predictable handling.Thebenefitsareanimmediateimprovementinbothve-hicleperformanceandsafety,aswellasincreaseddriver comfort —morepositive controlmeans lessdriverfatigue.

What do our customers say? “My F53 chassis would vibrate so bad that it shook the whole motorhome. The only way to stop the vibra-tion was to slow down to 20 mph — which almost got me rear-ended twice. Finally my wife told me, ‘I’m not riding in that motorhome any more.’ A mechanic told me about Davis TruTrac bars. I had one installed and the vibrations stopped imme-diately. I drove that motorhome for another 150,000 miles (with my wife back on board) and it was solid as a rock.”— John Kielty, Reno, Nevada

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All illustrationsandspecificationscontainedhereinarebasedonthelatestinformationavailableatthetimeofpub-lication. ROADMASTER, Inc. reserves the right tomakechanges,atanytime,withoutnotice,inmaterial,specifica-tionsandmodels,ortodiscontinuemodels.

“Wegetyourtowedcarthere,whilestoppingsafelyalongtheway.”

Towing and Suspension Solutions ROADMASTER,Inc.•6110NE127thAve•Vancouver,WA98682

800-669-9690•fax360-735-9300•roadmasterinc.com

Owner’s Manual - Roadmaster Inc. · rectly — the contact point at the bottom of the socket...

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