Installation Instructions Second Vehicle Kit Towing and Suspension Solutions

Installation Instructions Second Vehicle Kit Towing and Suspension Solutions
Second Vehicle Kit
with BrakeAway™ system — Part number 98160
Installation
Instructions
Towing and Suspension Solutions
ROADMASTER, Inc. • 6110 NE 127th Ave. • Vancouver, WA 98682
• 800-669-9690 • Fax 360-735-9300 • roadmasterinc.com
85-3902-03
04/11
© 2011 ROADMASTER, Inc. All rights reserved.
Welcome to the ROADMASTER family!
T
hese instructions have been prepared to acquaint you with the installation of your BrakeMaster second vehicle
kit, and to provide you with important safety information.
Read these instructions, as well as the owner’s manual and all accompanying literature, completely (The most
current version of the owner’s manual is available at www.roadmasterinc.com under ‘Support’). Understand how
to install and operate your BrakeMaster, and carefully follow the instructions and safety precautions.
Your BrakeMaster second vehicle kit has a one-year limited warranty. To qualify for your warranty, fill out and
return the enclosed product registration card within 30 days of purchase.
We thank you for your patronage and greatly appreciate your discerning taste.
Table of contents
Safety definitions...............................inside front cover
Before you begin the installation
(installer’s checklist)............................................... 1
Air cylinder assembly parts list................................... 2
Install the air cylinder anchor plate......................... 3-5
Install the break away system................................. 6-7
Install the air lines................................................... 8-9
Install the motorhome monitor wiring....................... 10
Test the system................................................... 11-12
Brake light solutions................................................. 13
Install six diodes.................................................. 14-15
Troubleshooting................................................... 16-18
Index......................................................................... 19
These instructions pertain to the initial installation of the second vehicle
components only. Operating instructions
are contained in the owner's manual; installation instructions for the complete
system are available at www.roadmasterinc.com.
Read all instructions before installing or operating
the BrakeMaster system. Failure to understand how
to properly install or operate BrakeMaster could result
in property damage, personal injury or even death.
IMPORTANT NOTICE!
Safety Definitions
These instructions contain information that is very important to know and understand. This information is provided for
safety and to prevent equipment problems. To help recognize this information, observe the following symbols:
CAUTION
WARNING indicates a potentially hazardous situation which, if not avoided, could result in property
damage, serious personal injury, or even death.
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in property
damage, or minor or moderate personal injury.
NOTE
Refers to important information and is placed in italic
type. It is recommended that you take special notice of
these items.
Before you begin the installation…
Note: this kit consists of the towed vehicle components only. The motorhome components of the BrakeMaster system must be installed and operating correctly
for BrakeMaster to function.
1. Always check the ROADMASTER web site — www.
roadmasterinc.com — for vehicle-specific information.
Select ‘Vehicle-Specific Info,’ then ‘Supplemental Braking Systems.' Enter the motorhome and towed vehicle
make, model and year, then scroll down the page.
2. If the battery must be disconnected for towing, a
stop light switch must be installed. Stop light switch kits
for most popular towed vehicles are available through
ROADMASTER; to see if one is available for any specific
vehicle, visit www.roadmasterinc.com. Select ‘VehicleSpecific Info,’ then ‘Supplemental Braking Systems.'
Enter the motorhome and towed vehicle make, model
and year, then scroll down the page.
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 stop light switch is still required; the
Brake-Lite Relay (see “Brake light solutions”) is not
required.
3. If the vehicle to be towed has an ‘active’ (or,
‘continuous power assist’) braking system, or if the
vehicle is not equipped with power brakes — order
the optional Brake Pressure Reducer (part number
900002) to adapt the vehicle to the BrakeMaster
system.
Vehicles with ‘active’ braking systems include several hybrid vehicles, such as the Ford Escape hybrid
and the Mercury Mariner hybrid, as well as the Hummer
H3. These vehicles, and others with these systems, are
designed so that even when the vehicle is set to ‘tow’
mode, the braking system is still active, thus requiring
minimal pressure to engage the brakes.
or if one is available, for the towed vehicle — visit
www.roadmasterinc.com. Select ‘Vehicle-Specific Info,’
then ‘Supplemental Braking Systems.' Enter the towed
vehicle make, model and year, then scroll down the
page.
6. Check the towed vehicle’s brake lights — BrakeMaster must function with the ignition key turned to the
“tow” position; however, some vehicles’ brake lights
only operate with the key turned to the “on” position.
Check to see if this is the case: turn the ignition
key to the “tow” position, apply the brakes, and check
to see if the brake lights illuminate. If the brake lights
do not illuminate, a two-prong stop light switch and
10-amp fuse must be installed.
Stop light switch kits for most popular towed vehicles are available through ROADMASTER; to see
if one is available for any specific vehicle, visit www.
roadmasterinc.com. Select ‘Vehicle-Specific Info,’ then
‘Supplemental Braking Systems.' Enter the towed vehicle make, model and year, then scroll down the
page.
Note: check the owner’s manual to see if the vehicle
is equipped with an “automatic shut down” feature. If
this is the case, ensure that the vehicle is not in automatic shut down mode before performing this test.
Note: if you must install a Brake-Lite Relay — see
step 7, below — a stop light switch is not required.
7. An optional Brake-Lite Relay may be required.
Refer to “Brake light solutions” for instructions on how
to determine if the relay must be installed.
Note: a stop light switch (see steps 2 and 6 above)
and a Brake-Lite Relay are mutually exclusive — if you
use one, the other is not necessary.
CAUTION
If the vehicle to be towed has an ‘active’ braking system, or if the vehicle is not equipped with
power brakes, install the optional Brake Pressure
Reducer.
If the reducer is not installed, BrakeMaster will
apply excessive force to the towed vehicle’s brake
pedal, causing severe tire and/or brake system
damage, as well as other consequential damage.
4. If fuse(s) must be removed from the vehicle before it can be towed — verify that removing the fuse(s)
will not disrupt power to BrakeMaster, or otherwise affect the installation or operation.
5. Optional seat adaptor brackets are required for
some towed vehicles and simplify the installation for
others. Determine if a seat adaptor bracket is required,
1
2
Install the air cylinder anchor plate
To determine where the anchor plate will be installed,
first attach the pedal clamp to the brake pedal. Follow
steps one through six below…
1. In the towed vehicle, slide the driver’s seat back as
far as it will go.
2. Verify that the pedal clamp is right side up, as shown
in Figure 1 — the arrow on the sticker will point “Up”
when the pedal clamp is properly positioned.
3. Pull the hairpin clip (Figure 1) out, then lift the slotted arm (Figure 1) up and out of the way.
4. Move the pedal clamp over the brake pedal. Then
hold the clevis (Figure 2) and pull back on the spring
post (Figure 2), until the tabs under the pedal clamp
are wide enough to clear the brake pedal.
5. Fit the pedal clamp onto the brake pedal, so that
all four tabs are hooked around it (Figure 3). Then,
release the spring post.
Note: on the initial installation, it may be necessary
to adjust the tabs on the pedal clamp — use pliers to
bend any or all of the tabs so that they hook around
and under the towed vehicle’s brake pedal.
Once the tabs have been adjusted to a specific
brake pedal, no further adjustment to the pedal clamp
is necessary for that vehicle.
If BrakeMaster is switched between towed vehicles,
always check the pedal clamp on the initial installation.
Verify that all four tabs are hooked around and under
the brake pedal. If necessary, bend the tabs to fit, as
described above.
Figure 1
Figure 2
CAUTION
Make certain that all four tabs on the pedal clamp
are securely hooked around the brake pedal (Figure
3). If the tabs are loose when the vehicle is towed,
the pedal clamp can rotate out of position and hold
the brake pedal down­­ — even when BrakeMaster is
not activated — which will cause tire and/or brake
damage or other consequential, non-warranty damage.
6. Swing the slotted arm back over the spring post, fit
the spring post through one of the slots, and reattach
the hairpin clip (Figure 3).
7. Now that the pedal clamp is in place, attach the
anchor plate (Figure 4).
Note: optional seat adaptor brackets are required
for some towed vehicles and simplify the installation for
others. Before attaching the anchor plate, determine if
a seat adaptor bracket is required — visit www.roadmasterinc.com. Select ‘Vehicle-Specific Info,’ then ‘Supplemental Braking Systems.' Enter the towed vehicle make,
model and year, then scroll down the page.
Choose a mounting point under the driver’s seat as
far back as possible — ideally, the anchor plate should
be concealed when the driver’s seat is moved forward,
and visible only when the driver’s seat has been moved
back as far as it will go.
Figure 3
BrakeMaster is shipped with the air cylinder at the
shortest position. If necessary, lengthen the reach of
the air cylinder to position the anchor plate at the point
you have chosen — remove the two bolts and nylon nuts
attaching the air cylinder to the adjustable arm (Figure
4). Slide the air cylinder (Figure 4) up the adjustable
arm until the anchor plate is over the point you have
chosen. Replace the two bolts and nylon nuts.
continued on next page
3
Install the air cylinder anchor plate
continued from preceding page
Note: if BrakeMaster is switched between towed
vehicles, it may be necessary to lengthen or shorten
the reach of the air cylinder, as described above. Two
additional safety pins (part number 356997-00) are
included, to replace the two bolts and nylon nuts —
the pins will secure the air cylinder to the adjustable
arm quickly, without having to thread and unthread the
bolts.
Note: if the vehicle is equipped with an automatic
pedal positioning system, adjust the brake pedal to its
farthest extension (as close as possible to the driver’s
seat) before positioning the air cylinder and the mounting post. This will eliminate the possibility of positioning
the anchor plate too close to the brake pedal.
8. Next, if necessary, move the air cylinder to the left
or the right, until the mounting post (Figure 4) is directly
in line with the brake pedal.
CAUTION
The air cylinder must be mounted directly in line
with the brake pedal. If it is mounted at an angle
to the brake pedal (to one side or the other), the
air cylinder may jam in the extended position when
BrakeMaster is activated, which will cause severe
brake system damage, as well as other consequential, non-warranty damage.
Note: the anchor plate can be rotated clockwise or
counterclockwise, if necessary, to clear any obstructions — to rotate the anchor plate, remove the air cylinder and lock the plate in a vise. Use a half-inch openend wrench to loosen the mounting post, while holding
the retaining screw (at the bottom of the plate) with an
Allen wrench. Do not turn the retaining screw with the
Allen wrench, as you may damage the wrench or the
screw. When the mounting post is loose, rotate the
anchor plate. Then, tighten the mounting post.
9. Before attaching the anchor plate, verify that the
following conditions are met:
A. Make certain that the pedal clamp is not de-
Figure 4
4
pressing the towed vehicle’s brake pedal — examine the
brake pedal, and also check the towed vehicle’s brake
lights to make certain they are not illuminated.
Make certain that the pedal clamp is not depressing the towed vehicle’s brake pedal.
If the pedal clamp is pushing the brake pedal
down, the brakes will be applied continuously when
BrakeMaster is connected, which will cause severe
tire and/or brake system damage, as well as other
consequential, non-warranty damage.
Failure to follow these instructions may cause
property damage, personal injury or even death.
B. When it is connected, the air cylinder must be
pulled back toward the anchor plate in order to insert
the safety pin (Figure 4) through the mounting post.
CAUTION
The air cylinder must be pulled back when it is
connected in order to create sufficient spring tension to keep the weight of the cylinder off the brake
pedal. If the cylinder is not pulled back when it is
connected, the weight of the cylinder may cause
the pedal clamp to depress the towed vehicle’s
brakes continuously, which will cause excessive
brake wear, brake system damage or other consequential, non-warranty damage.
C. The pedal clamp must be flat against the brake
pedal and properly secured with the hairpin clip (Figure
3).
D. Make certain that there is sufficient clearance
between the mounting post and the bottom of the seat
to allow the seat to slide properly.
10. Once the four conditions in step 9 (above) are met,
attach the anchor plate. (It may be helpful to remove the
driver’s seat to facilitate the rest of the installation.)
The anchor plate can be attached on top of the
carpet, or underneath it.
A. To mount the plate on top of the carpet, first
use the anchor plate as a template and mark the five
holes to be drilled.
Before drilling, make certain that the retaining screw
(at the bottom of the mounting post) is fully tightened.
(To tighten the screw, reverse the instructions in step 8,
above.) Also, make certain that you will not drill through
any wiring or electrical components underneath the
carpeting, or damage any components on the other
side of the floorboard.
Do not drill through any wiring. The air bag sensor wire may be located under the driver’s seat.
Drilling into this wire may disable the air bag syscontinued on next page
Install the air cylinder anchor plate
continued from preceding page
tem, or may cause the air bags to deploy immediately, which may cause severe personal injury.
Failure to follow these instructions may cause
property damage, personal injury or even death.
Next, drill five ¼" holes at the points you marked.
Drill through the carpet and the floorboard. Use caution
to prevent the drill bit from catching on threads in the
carpet and unraveling it.
B. If mounting the anchor plate underneath the
carpet, cut a small flap in the carpet to allow the
mounting post to protrude through it.
As described above, use the anchor plate as a template, and drill five ¼" holes through the floorboard.
11. Next, attach the anchor plate as shown in Figure
5, using the provided ¼" x 1" hex head bolts and self-
locking flange nuts.
12. If you find that tightening the flange nut on a bolt
is difficult due to a tube, channel or other obstruction under the floorboard, use one of the provided jack
Figure 5
standard
installation
nuts to attach the bolt. Refer to Figure 6.
Note: if one or more jack nuts are used, the anchor
plate cannot be mounted on top of the carpet.
To attach a bolt with a jack nut, drill a ½" hole
through the floorboard at the point you marked in step
10.
Note: do not drill out the hole in the anchor plate.
Next, insert the jack nut into the hole (see Figure
6) and bolt through the anchor plate, using one of the
¼" x 1" hex head bolts.
13. This completes the anchor plate installation. You
can leave the air cylinder assembly in place — it must be
attached to install an air line fitting in a later step — or
you can remove it if it interferes with the installation.
Automatic pedal positioning systems may affect
the towed vehicle braking system.
Determine if the vehicle to be towed is equipped
with pedal presets. Proper connection of the braking system may be affected by these presets; if
the vehicle is so equipped, note the original install
position and return to that position before towing
the vehicle.
If the brake pedal is not at the original install
position when the vehicle is towed, the pedal clamp
may apply excessive braking force, which will damage the brake system and/or electrical system, and
may cause brake or electrical system failure, as
well as other non-warranty damage.
Failure to follow these instructions may cause
property damage, personal injury or even death.
drill 1/4" hole
Figure 6
jack nut
installation
note: do not
drill out the
hole in the
anchor plate!
drill 1/2" hole
5
Install the break away system
Step A
Install the air reservoir
1. First, choose a location for the air reservoir (Figure
7). The air reservoir is mounted in the towed vehicle,
most often in the engine compartment, but it may be
attached anywhere an air line can be routed from the
top of the air reservoir to the front of the vehicle, and
where the drain valve (Figure 7) at the bottom of the
reservoir is easily accessible.
Choose a location that meets the following conditions:
• An air line will be attached to the reservoir in a later
step. One end will be routed to the driver’s side of the
passenger compartment; the other end will be routed
to the front of the vehicle. This air line cannot be closer
than two feet to any heat source, such as the engine
or exhaust system, which might damage the air line.
• The air reservoir must be mounted away from any
moving parts, so that the air reservoir will not be damaged by, or interfere with, the proper operation of any
components.
• Choose a location that will allow the bottom of the
air reservoir to be mounted lower than the top, so that
any accumulated water can be drained from the tank.
The reservoir cylinder does not have to be perfectly
straight up and down, but the drain valve must be the
lowest part of the reservoir.
• The reservoir will be attached with two of the supplied ¼" x 1" hex bolts and nuts. Choose a location
that will allow you sufficient access to tighten the hex
nuts from the other side.
Note: because the air reservoir will be charged with
compressed air, it cannot be mounted inside the passenger compartment of the vehicle.
2. Once you have chosen a location for the air reservoir, fold the two rubber clamps (Figure 7) over the
cylinder. Press the ends of each clamp together, until
the pre-drilled holes align.
Figure 7
Test-fit the reservoir and slide the clamps up or
down the cylinder, if necessary, until the pre-drilled
holes are both over a surface where the hex bolts and
nuts will hold each clamp in place. Mark the center of
each hole for drilling, and set the reservoir aside.
Before drilling, make certain you will not damage
any components on the other side. Then, drill a ¼" hole
through the two points you have marked.
Before attaching the clamps, rotate the top of the
reservoir so that the two wires at the solenoid valve
(Figure 11), as well as the two brass air compression
fittings (Figure 11), will be easily accessible.
Position the reservoir and clamps over the two
holes and secure the reservoir in place with one of
the ¼" x 1" hex bolts and nuts at each clamp.
Step B
Mount the break away switch
1. Mount the break away switch (Figure 7) at the front
of the vehicle, on the driver’s side. Choose an area you
can easily reach, with a surface of sufficient strength to
hold the switch firmly in place, so that the break away
pin (Figure 7) will pull freely from the switch. Mount the
switch in a horizontal position, with the break away pin
facing toward the motorhome.
Ensure that the break away pin can be pulled freely away from the towed vehicle without any obstructions.
Do not attach the break away switch to the tow
bar or the tow bar bracket. If the tow bar or bracket
fails, the break away switch will separate with it,
preventing the break away system from activating.
If the towed vehicle separates, the brakes will not
be applied, which may cause property damage,
personal injury or even death.
Step C
Connect the wiring
1. Using one of the blue butt connectors, attach one
end of the supplied length of 14-gauge black wire to the
end of either one of the two wires extending from the
break away switch. (If necessary, strip 1/4" to 3/8" of
insulation from the end of the wires before connecting
them).
Next, route the wire to the positive terminal on the
towed vehicle’s battery (Figure 8), avoiding moving
parts, sharp edges or “hot” components such as the
engine or exhaust system. Where appropriate, use one
or more of the included wire ties to secure the wire in
place.
2. Cut the wire and strip ¼" to 3/8" of insulation from
the end of the wire. Crimp either end of the supplied
continued on next page
6
Install the break away system
continued from preceding page
yellow 10-amp fuse onto the end of the wire. Strip ¼"
to 3/8" of insulation from one end of the remaining
length of wire; crimp the other end of the fuse onto
the wire.
3. If necessary, cut the wire again, leaving no more
than six inches, and strip ¼" to 3/8" of insulation from
the end of the wire. Crimp the larger (3/8") ring terminal
onto the end of the wire, and attach the ring terminal to
the positive terminal on the towed vehicle’s battery.
In order to prevent damage from a short circuit,
the 10-amp fuse must be within six inches of the
positive terminal. If the 10-amp fuse is farther than
six inches, a short circuit may cause significant
damage to the towed vehicle’s electrical system, an
electrical fire or other consequential, non-warranty
damage.
the length of the ground wire).
6. If the battery must be disconnected for towing, install a battery switch to the positive battery cable, as
shown in Figure 9. Connect the stop light switch wiring
to the battery switch.
If the battery must be disconnected for towing,
a battery switch must be connected as shown in
Figure 9. If it is not, the break away system will not
function if the towed vehicle separates, which may
cause property damage, personal injury or even
death.
4. Now, connect the remaining wire at the break away
switch to either one of the two wires extending from the
top of the solenoid valve on the air reservoir (Figures
8 and 11). If necessary, use the remaining length of
14-gauge black wire to reach the top of the solenoid
valve. As before, strip the ends of the wires before connecting them with the supplied blue butt connectors.
Where appropriate, use one or more of the included
wire ties to secure the wire in place.
5. Crimp the smaller (#10) ring terminal onto the end
of the remaining wire extending from the top of the
solenoid valve, and attach the ring terminal to any good
chassis ground. (If necessary, use another butt connector, and any remaining 14-gauge black wire, to extend
Figure 8
Figure 9
7
Install the air lines
1. Find a suitable location at the front of the towed
vehicle to attach the preassembled male quick coupler
(Figure 10). Choose an area within easy reach, with
a surface of sufficient strength to hold the mounting
bracket firmly in place.
Do not attach the female quick coupler at the
front of the towed vehicle. The female quick coupler has an internal check valve to prevent air
from escaping. If air pressure is not released, the
BrakeMaster pedal clamp will not retract when the
system is activated, which will cause severe brake
system damage or a brake fire, as well as other
consequential, non-warranty damage.
Failure to follow these instructions may cause
property damage, personal injury or even death.
2. Attach the bracket with two of the supplied ¼" nuts
and bolts, with the male quick coupler pointing away
from the towed vehicle.
Note: the weather covers will prevent dirt or debris
from entering the lines. Keep the fittings covered when
the braking system is not in use.
3. Connect one end of the air line to the male quick
coupler compression fitting (Figure 10) — first, if necessary, trim the end of the air line, to make a smooth and
straight cut. Then, slide the compression nut and the
ferrule (Figure 10) over the air line. Position the ferrule
¼" from the end of the air line.
Next, slide one of the brass inserts (Figure 10) into
the end of the line.
Note: if the brass inserts are omitted, the fittings
will not be airtight.
Now, push the air line into the compression fitting
as far as it can go. Then push the ferrule into the
compression fitting, and tighten the compression nut
onto the fitting.
Note: if the compression nut is overtightened, the
fitting will not be airtight. After completing the installation, check all the fittings for air leaks — see “Test the
system.”
Figure 10
8
4. Tape the open end of the air line. Then route the
air line from the male quick coupler to the break away
air reservoir, avoiding moving parts, sharp edges or
“hot” components such as the engine or the exhaust
system. Do not kink the air line, or bend it to the extent
that it crimps or creases. Where appropriate, use wire
ties to secure the air line in place.
CAUTION
Do not position the air line closer than two feet
from any heat source. The heat will soften the plastic, which will cause the air line to rupture.
If the air line is ruptured, the supplemental braking system will not function.
Do not kink the air line, or bend it to the extent
that it crimps or creases — air pressure will be substantially reduced, or blocked entirely, at the kink
in the line.
If the air pressure is reduced, the supplemental
braking system will not function, or may only function intermittently.
5. At the top of the break away air reservoir (Figure
11), cut the air line to length and attach the open end
to the brass “air in” compression fitting (Figure 11). Use
the same method described in step 3 (above) to attach
the air line.
6. Next, attach the end of another section of air line
to the brass “air out” compression fitting on the top of
the break away air reservoir (Figure 11). Use the same
method described in step 3 (above) to attach the air
line.
7. Tape the open end of the air line. Then, route the
air line from the break away air reservoir through the
engine compartment and to the driver’s side of the
firewall. As before, avoid moving parts, sharp edges or
“hot” components such as the engine or the exhaust
system. Do not kink the air line, or bend it to the extent
that it crimps or creases.
Where appropriate, use wire ties to secure the air
line in place.
continued on next page
Figure 11
Install the air lines
continued from preceding page
8. Next, look for a pre-existing hole in the firewall (or,
if there is sufficient space, a pre-existing wiring grommet) on the driver’s side, to route the air line through
the firewall.
If there is no pre-existing hole or grommet with sufficient space, drill a ½" hole through the firewall.
Drill from the engine compartment or from the interior of the vehicle, whichever is more convenient.
Before drilling, make certain you will not damage any
components on the other side of the firewall.
9. Fit the included firewall grommet into the ½" hole,
and push the end of the air line through.
10. The air line will be connected to the preassembled
female quick coupler (Figure 12) —
Find a likely mounting point for the bracket on the
driver’s side — choose an area within easy reach, with
a surface of sufficient strength to hold the mounting
bracket firmly in place.
The bracket and quick coupler must not present
an obstacle or hazard to the driver of the vehicle, or
otherwise interfere with the operation of the vehicle.
Two common mounting points are: 1) under the
dashboard, on the kick panel; or 2) far enough under
the front of the driver’s seat so that the quick coupler
is accessible when the seat is slid back, but concealed
when the seat is slid forward.
Or, depending on the interior design of the vehicle,
there may be a more suitable mounting point.
Before attaching the bracket, first connect the
BrakeMaster air cylinder assembly. Make certain that
the male quick coupler at the end of the air line will
reach the point you have chosen to attach the female
quick coupler, without kinking either of the air lines.
Note: the quick exhaust valve on the air cylinder
(see page 2) may be rotated, if this provides an easier
connection.
Before attaching the coupler, make certain you will
not damage any components on the other side.
If you have chosen to attach the bracket under the
driver’s seat, make certain that the female quick coupler
and bracket will not interfere with the normal movement
of the driver’s seat, or affect any adjustments to the
driver’s seat.
• If you have chosen to attach the bracket to the kick
panel, attach it with two of the supplied ¼" nuts and
bolts, with the female quick coupler pointing toward the
rear of the towed vehicle.
• If you have chosen to attach the bracket under the
driver’s seat, route the air line from the firewall to the
front edge of the driver’s seat. Remove the rocker panel
or side trim (or, detach the carpeting) and conceal the
air line underneath it.
Move the driver’s seat back as far as it will go.
Attach the bracket with two of the supplied ¼" nuts
and bolts, with the female quick coupler pointing toward
the front of the vehicle.
11. Cut the air line to length and attach it to the compression fitting on the female quick coupler. Use the
same method described in step 3 (above) to attach the
air line.
12. Seal the firewall grommet with a silicone sealant.
Reattach the rocker panel (or side trim or carpeting),
if it was removed.
Note: the weather covers will prevent dirt or debris
from entering the lines. Keep the fittings covered when
the braking system is not in use.
Figure 12
9
Install the motorhome monitor wiring
1. Choose a mounting point at the front of the vehicle
near the male quick coupler you attached in step 2,
“Install the air lines,” for the end of the supplied length
of black wire with a female bullet connector at one end.
Attach the connector with one or more of the included
wire ties. Allow enough slack so that a male bullet
connector can be plugged into and out of it.
2. Once the female bullet connector is attached, route
the monitor wiring harness through the engine compartment, to the driver’s side of the firewall. Use the same
route as the air line, if that is convenient. As before,
avoid lines, hoses, moving parts or “hot” components
such as the engine or exhaust systems. Where appropriate, use wire ties to secure the wiring harness
in place.
3. Route the monitor wiring harness through the same
hole as the air line.
4. Before connecting the monitor wiring harness to the
brake light wire, determine if the optional Brake-Lite Relay must be installed — refer to “Brake light solutions,”
in these instructions, for information on how to identify
the type of brake and turn signals in the vehicle. Then,
test the towed vehicle’s brake lights, as described in
“Brake light solutions.”
Several wiring alternatives are available to you,
based on the type of brake and turn signals in the
vehicle and the results of the test.
5. Next, locate the towed vehicle’s brake light switch
and, with a test light, find the “cold” side of the brake
light switch. (The “cold” side of the switch does not
register voltage unless the brakes are applied.) With
a 12-volt meter, verify that you have found 12 VDC+.
Then, remove the vehicle’s brake light fuse, located
in the vehicle’s fuse panel.
CAUTION
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 indicators, to be activated if the brake pedal is depressed during the installation. This may require
non-warranty repair to the vehicle.
6. Cut the brake light wire, a few inches downstream
from the “cold” side of the brake light switch.
If the Brake-Lite Relay is required…
(see step 4, above)
Install the Brake-Lite Relay now — installation instructions are included in the kit. After the relay is installed,
proceed to the next section — “Test the system.”
If the Brake-Lite Relay is not required…
(see step 4, above)
7. If necessary, trim the monitor wiring harness, then
attach the monitor wire to the brake light wire, using
the supplied yellow butt connector.
10
8. Ensure that the monitor wiring harness will not present an obstacle or hazard to the driver of the vehicle,
or interfere with the operation of the vehicle. Use one
or more wire ties, if necessary, to secure the wiring
harness out of the way.
9. Reinstall the brake light fuse, which you removed
in step 5.
10. The installation is complete. Before towing, proceed
to the next section — “Test the system.”
Test the system
Note: this kit consists of the towed vehicle components only. In order to complete the system test, the
motorhome components must be installed and operating correctly for BrakeMaster to function.
Note: refer to the complete installation instructions to
identify the motorhome components you will connect.
The most current version of the instructions is available
at www.roadmasterinc.com.
CAUTION
Always deplete the stored vacuum in the towed
vehicle’s power brake system before towing — pump
the brake pedal several times.
Depending on the make and model of the towed
vehicle, it may be necessary to pump the brake
pedal repeatedly to deplete the vacuum.
If the vacuum is not released, the supplemental
braking system will apply excessive braking force
when it is activated, which will cause severe tire
and/or brake system damage to the towed vehicle.
1. The motorhome and towed vehicle must be stationary for the system test, and ready for towing.
A. All components of the braking system must be
properly connected —
• Connect and attach the tow bar to both vehicles.
Then, according to the manufacturer, make all adjustments necessary to prepare the vehicle for towing.
These adjustments may include: turning the ignition
key to the “tow” position; pulling fuses; disconnecting
the battery; and setting the transmission to a particular
gear or in a particular sequence.
Refer to the owner's manual or call the dealership
for vehicle-specific information.
CAUTION
To prevent the towed vehicle from rolling, connect and attach the tow bar to both vehicles before
shifting the towed vehicle’s transmission into the
proper gear for towing.
• Connect the patch cord between the two vehicles
— both the air line quick couplers and the motorhome
monitor bullet connectors.
• Attach the air cylinder to the brake pedal and
mounting post (or seat bracket adaptor). Connect the
male quick coupler at the end of the air line on the air
cylinder to the female quick coupler at the end of the
air line mounted in the passenger compartment.
• Clip one end of the steel break away cable to
the break away pin (Figure 7); clip the other end of
the cable to the rear of the motorhome, close to the
center.
B. For motorhomes with hydraulic brakes (BrakeMaster 9060): turn the motorhome engine on, and leave
it running. Turn the towed vehicle’s ignition key to the
“tow” position.
For motorhomes with air or air over hydraulic
brakes (BrakeMaster 9100 and 9160): block the motorhome wheels, then release the parking brake. Turn the
motorhome engine on, and leave it running.
2. Check for leaks in the towed vehicle’s air line: allow
the air compressor to run until it shuts off. Then, apply
the motorhome brakes and continue to hold the brake
pedal down.
Cover each joint, fitting and connection in the towed
vehicle’s air line with a leak check solution.
The air system now contains pressurized air,
which may cause severe eye or ear injury if it is
inadvertently released. Wear appropriate eye and
ear protection before adjusting the air system connections and fittings.
Tighten any fittings, if necessary, and repeat until
all connections are airtight.
3. Confirm the proper operation of the braking system:
depress and hold the motorhome brake pedal down.
At the towed vehicle, the air cylinder shaft and pedal
clamp will extend. Then, release the brake pedal. The
air cylinder shaft and pedal clamp will retract.
4. Confirm that the motorhome monitor is functioning:
the LED will illuminate after the motorhome brake pedal
is depressed, and stop illuminating when the brake
pedal is released.
If the LED does not illuminate, as described
above, identify and correct the cause of the malfunction before using the supplemental braking
system. Refer to the Troubleshooting section for
possible causes.
The LED is the only indication of braking activity at the motorhome. Severe damage to the
towed vehicle, a loss of vehicular control or other
consequential, non-warranty damage can occur if
the driver of the motorhome is unaware that the
supplemental braking system is not functioning
properly.
Failure to follow these instructions may cause
property damage, personal injury or even death.
5. Confirm the proper operation of the break away
system —
Charge the break away air reservoir — start the motorhome and allow the air compressor to run until it
shuts off. Then, apply the motorhome brakes and hold
the brake pedal down.
The break away air reservoir must be charged,
continued on next page
11
Test the system
continued from preceding page
as described above, every time the motorhome and
towed vehicle are connected. If the air reservoir is
not charged, the break away system will not apply
breaking pressure if the towed vehicle separates
from the motorhome, which may cause property
damage, personal injury or even death.
Next, remove the break away pin (Figure 7) at the
front of the break away switch. The air cylinder and
pedal clamp will extend, confirming the proper operation of the break away system.
To retract the air cylinder and pedal clamp, briefly
disconnect the quick couplers from the air line extending from the air cylinder. Then, reconnect the break
away pin.
Before towing, charge the break away air reservoir,
as described above.
6. Confirm the proper operation of the towed vehicle’s
brake lights and turn signals —
A. Depress the motorhome brake pedal; confirm
that the towed vehicle’s brake lights illuminate. Activate
both motorhome turn signals; confirm that the towed
vehicle’s turn signals activate.
If the towed vehicle’s brake lights and turn signals
do not operate in tandem with the motorhome, you
must install a non-intrusive lighting system or re-wire
the towed vehicle. See “Brake light solutions.”
B. With one of the motorhome turn signals activated, depress the motorhome brake pedal. Confirm
that the towed vehicle’s brake lights and turn signal
both illuminate.
If the towed vehicle’s brake lights override the turn
signal, you must install a non-intrusive lighting system
or re-wire the towed vehicle. See “Brake light solutions.”
By law, a towed vehicle’s turn signals and brake
lights must operate in tandem with the motorhome’s, as described above. If they do not, drivers
behind the towed vehicle will not be alerted when
the motorhome stops or turns, which may cause a
collision.
If the towed vehicle’s brake lights and turn signals do not operate in tandem with the motorhome,
either install a non-intrusive lighting system or rewire the towed vehicle according to the next section, “Brake light solutions.” Then test for proper
operation, as described in step 6, above.
Failure to follow these instructions may cause
property damage, personal injury or even death.
12
Brake light solutions
A supplemental braking system will affect the opera-
tion of the vehicle’s tow lighting system. Use the information below to determine if optional components
must be installed in a vehicle which has been wired for
towing — or, if no lighting system has been installed,
which systems are appropriate.
1. First, identify the type of brake and turn signals in the
vehicle. There are two types — combined or separate.
In a combined system (Figure 13), the brake light does
the flashing for the turn signal; in a separate system
(Figure 13), there are amber or red turn signal lights
which are separate from the brake lights.
2. Next, test to see if the towed vehicle’s brake lights
will illuminate with the engine off — with the ignition key
at the “tow” position, press the brake pedal and check
the brake lights.
3. Based on whether or not the brake lights illuminate,
and the type of brake and turn signals, there are three
possibilities:
• the brake lights illuminate and the towed vehicle
has combined lighting;
• the brake lights illuminate and the towed vehicle
has separate lighting; or
• the brake lights do not illuminate.
There are a number of lighting methods available
for each of these three possibilities; they are described
below.
(If you choose to install a Universal Wiring Kit, a
Taillight Wiring Kit, magnetic tow lights or the BrakeLite Relay, complete installation instructions and wiring
diagrams are included with the kits; this information is
also available online at www.roadmasterinc.com.)
If the brake lights illuminate and the
towed vehicle has combined lighting…
…one of the three alternatives below is required:
• A Universal Wiring Kit (part number 154) with a
Brake-Lite Relay — a system of diodes is installed to
rewire the vehicle’s turn signals, taillights and brake
lights for towing.
• Install an optional “bulb and socket set” (also called
a “taillight wiring kit,” part number 155).
• Install an optional magnetic tow light system (part
number 2100 or 2120).
If the brake lights illuminate and the
towed vehicle has separate lighting…
…one of the four alternatives below is required:
• A Universal Wiring Kit (part number 154) with a
Brake-Lite Relay — a system of diodes is installed to
rewire the vehicle’s turn signals, taillights and brake
lights for towing.
• Install six diodes, and jump the diodes. See page
14.
• Install an optional “bulb and socket set” (also called
a “taillight wiring kit,” part number 155).
• Install an optional magnetic tow light system (part
number 2100 or 2120).
If the brake lights do not illuminate…
…an optional stop light switch must be installed.
Stop light switch kits for many vehicles are available
through ROADMASTER; visit www.roadmasterinc.com
for the most current list.
Any one of the following tow lighting systems must
also be installed with the stop light switch:
• A Universal Wiring Kit (part number 154) — a system
of diodes is installed to rewire the vehicle’s turn signals,
taillights and brake lights for towing.
• An optional “bulb and socket set” (also called a “taillight wiring kit,” part number 155)
• An optional magnetic tow light system (part number
2100 or 2120)
Figure 13
13
Install six diodes
Note: this wiring method can only be used if the
brake lights illuminate with the engine off and the towed
vehicle has separate lighting. See page 13.
Note: if the motorhome has combined brake and
turn signals, use Figure 14 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 14.
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 installed.
1. Cut the factory turn signal, taillight and brake light
wires, as close to the lights as possible.
2. Install the six diodes in line, as shown in Figure 14.
Install the diodes as close to the lights as possible.
CAUTION
Attach the diodes as close to the vehicle’s
Figure 14
14
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 farther away may cause the
towed vehicle’s lights to work improperly and may
also cause damage to other electrical components
in the vehicle.
3. On each side, jump the brake and turn signal diodes, as shown in Figure 14.
CAUTION
Unless the brake and turn signal diodes are
jumped, the towed vehicle’s brake light circuits will
override the motorhome’s turn signals — the towed
vehicle’s turn signals will not operate in conjunction with the motorhome’s turn signals, as required
by law.
4. Test the installation…
A. If the motorhome has a combined lighting system (Figure 13)…
1. The towed vehicle’s turn signals and brake
lights will both flash (each side) when the motorhome’s
continued on next page
Install six diodes
continued from preceding page
turn signal is on; and
2. When the motorhome’s turn signal and brake
signal are both on (each side), the towed vehicle’s
brake lights will stay illuminated, while the turn signal
flashes.
B. If the motorhome has a separate lighting system
(Figure 13), the towed vehicle’s turn signals and brake
lights will illuminate identically to the motorhome’s.
15
Troubleshooting
Symptom
The motorhome monitor LED does not illuminate,
even though the brakes in the towed vehicle are being
applied.
Solution
1. The monitor LED will not illuminate during very light
braking.
2. Make certain that the monitor patch cord is securely
connected between the two vehicles.
3. The towed vehicle-to-motorhome electrical cord
must also be connected — the monitor system uses it
for the ground wire.
4. The monitor LED is connected to the towed vehicle’s
brake light circuit. If the fuse in the circuit is blown,
the LED will not illuminate. Check the towed vehicle’s
brake lights — if they illuminate when the brake pedal
is depressed, the fuse is good.
5. Did you install the optional Brake-Lite Relay? If so,
make certain that the monitor wire is connected to the
towed vehicle’s brake light wire after the brake light
switch, but before the Brake-Lite Relay — connecting
the wire anywhere else will prevent the monitor LED
from functioning.
Symptom
Nothing happens after proper installation.
Solution
1. The motorhome engine must be running — if the
engine is off, there may be insufficient pressure to activate BrakeMaster.
2. Check the air line connections. Remove the weather
covers from the quick couplers at both vehicles, and
gently tug on the air line to verify that the quick couplers
are connected.
Check to make certain that the air cylinder quick
coupler is connected to the air line in the passenger
compartment.
3. For motorhomes with hydraulic brakes (BrakeMaster
9060) —
A. Check the wiring at the solenoid valve (on the
proportioning valve). One of the black wires must be
connected to a good chassis ground (Figure 15). The
other black wire must be connected to the motorhome
brake wire downstream from the brake light switch.
Use a test light to confirm that the solenoid valve is
receiving power when the motorhome brake pedal is
depressed.
If the connections are good, test for proper function — with the motorhome engine running, have an
assistant depress the motorhome brake pedal while
you listen for a “click” at the solenoid valve. The solenoid valve should “click” every time the brake pedal is
depressed.
B. Disconnect the air line from the “out” compression
fitting on the solenoid valve (Figure 15). Have an assistant depress the motorhome brake pedal — the proportioning valve should release air each time the pedal
16
Figure 15
Figure 16
is depressed.
• If there is air at the proportioning valve — follow the
air line back to the air cylinder in the towed vehicle.
Inspect the entire line for deformities caused by excessive heat and/or kinks in the line, which would restrict
the air flow — replace the entire section of air line if
any are found.
Disconnect the quick couplers to confirm that they
are allowing air to flow through them.
• If there is no air at the proportioning valve — check
to confirm that the air line between the air compressor and the proportioning valve is connected to the
correct fitting. It should run from the “in” fitting on the
air compressor (Figure 16) to the “in” fitting on the
proportioning valve (Figure 17).
If the air line is connected to the “out” fitting on the
proportioning valve, no air can pass through the valve,
continued on next page
Troubleshooting
continued from preceding page
nd the BrakeMaster system will not function.
a
If this is the case, reconnect the line from the air
compressor to the “in” fitting on the proportioning valve.
Figure 17
Symptom
The compressor (for motorhomes with hydraulic
brakes — BrakeMaster 9060) runs constantly, or runs
much more frequently than I think it should.
Solution
1. Check for leaks in the air system.
2. Make certain that the drain valve on the air compressor air tank is closed. Refer to Figure 18.
3. Make certain that the drain valve on the BreakAway
air reservoir is closed. Refer to Figure 7.
4. Make certain that a female quick coupler has been
installed at the rear of the motorhome — a male quick
coupler does not have a check valve to prevent air from
escaping.
Symptom
It seems to require a significant amount of brake
pressure in the motorhome before the BrakeMaster air
cylinder activates in the towed vehicle.
Solution
1. The motorhome engine must be running — if the
engine is off, there may be insufficient pressure to activate BrakeMaster.
2. Inspect the air lines for deformities caused by excessive heat and/or kinks in the line, which would restrict
the air flow — replace the entire section of air line if
any are found.
3. Check for leaks in the air system: after starting the
motorhome, allow the air system to fully charge. Depress and hold the motorhome brake pedal down.
Cover each joint, fitting and connection in the air
system with a leak check solution.
Tighten any fittings, if necessary, and repeat until
all connections are airtight.
4. For motorhomes with hydraulic brakes (BrakeMaster
9060) — If the towing vehicle is a Ford Class C motorhome, the proportioning valve must be teed into the
front hydraulic brake line — the rear brake line does not
supply sufficient hydraulic pressure.
5. For motorhomes with hydraulic brakes (BrakeMaster
9060) — Not all of the air was bled from the brakes
after installing the proportioning valve. Re-bleed the
proportioning valve, as well as all brakes (and any components connected to the braking system) downstream
from the brake tee. Refer to the complete BrakeMaster
installation instructions (at www.roadmasterinc.com) for
instructions on bleeding the valve and the brakes.
Symptom
The BrakeMaster air cylinder shaft will extend, and
the pedal clamp will depress the towed vehicle’s brake
pedal. However, the air cylinder shaft will not retract
Figure 18
when the motorhome brake pedal is released.
Solution
1. Make certain that the air cylinder has been installed
directly in line with the brake pedal. If it is mounted at
an angle to the brake pedal (to one side or the other),
the air cylinder may jam in the extended position.
2. Dirt or debris can enter the air lines if the weather
covers are not used over the quick couplers. It may
accumulate at the quick exhaust valve (see page two)
on the air cylinder, preventing the valve from venting air
out of the air cylinder. Disassemble the quick exhaust
valve and make certain it is not jammed.
3. If a system of diodes was used to wire the towed
vehicle’s lights for towing, make certain that a diode
is installed at every point where the motorhome brake
light wire connects to the towed vehicle’s brake light
wire (refer to Figure 14).
When the air cylinder shaft extends and the pedal
clamp depresses the towed vehicle’s brake pedal, it
energizes the towed vehicle’s brake light wire. If diodes are not installed in the circuit, current will travel
back to the motorhome and activate the BrakeMaster
continued on next page
17
Troubleshooting
continued from preceding page
s olenoid.
As long as the solenoid is activated, it will not allow
air to vent from the air cylinder — the air cylinder shaft
will remain extended.
Symptom
The towed vehicle brakes abruptly the first time
BrakeMaster is activated, ‘flat-spotting’ the tires. Also,
after towing, there may be excessive brake dust on the
wheels of the towed vehicle, and/or an unusual odor
near the towed vehicle’s brakes.
Solution
1. The stored vacuum in the towed vehicle’s power
brake system must be depleted before towing — pump
the brake pedal several times. Depending on the make
and model of the towed vehicle, it may be necessary
to pump the brake pedal repeatedly.
Deplete the vacuum in the power brakes every time
the towed vehicle’s engine has been started — typically,
when the vehicle is connected for towing.
The engines in some vehicles, such as the Saturn
Vue, must be started periodically during towing. 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.
Refer to the caution statement on page 11.
2. If the towed vehicle has an ‘active’ (or, ‘continuous
power assist’) braking system, order the optional Brake
Pressure Reducer (part number 900002) to adapt the
vehicle to the BrakeMaster system.
Vehicles with ‘active’ brake systems include several
hybrid vehicles, such as the Ford Escape hybrid and
the Mercury Mariner hybrid, as well as the H3 Hummer. These vehicles, and others with ‘active’ braking
systems, are designed so that even when the ignition
is turned to the “tow” position, the braking system is
still active.
If the Brake Pressure Reducer is not installed,
BrakeMaster will apply excessive force to the towed
vehicle’s brake pedal.
3. If the towed vehicle does not have power brakes,
order the optional Brake Pressure Reducer (part number 900002) to adapt the vehicle to the BrakeMaster
system. BrakeMaster is designed to work with vehicles
that have a power brake system (even though the power
brakes are not activated while towing).
If the reducer is not installed, BrakeMaster will apply
excessive force to the towed vehicle’s brake pedal.
18
Index
3-to-2 converter — test to determine
if installed in motorhome...................................... 14
‘Active’ braking systems............................................. 1
Air cylinder —
Adjusting length................................................... 3-4
Anchor plate
Initial installation.............................................. 3-5
Retaining screw............................................... 4-5
Rotating.............................................................. 4
Parts list................................................................. 2
Quick exhaust valve — rotating............................... 9
Air lines —
Check for leaks.................................................... 11
Connecting to the quick couplers........................... 8
Initial installation.................................................. 8-9
Automatic Battery Disconnect —
when to install........................................................ 1
Battery disconnected for towing,
wiring schematic..................................................... 7
Brake light solutions................................................. 13
Brake light switch — finding “cold” side..................... 10
Brake-Lite Relay —
determine if the relay must be used..................... 13
Brake Pressure Reducer — when to use.................... 1
Break away system —
Air reservoir — choosing a mounting location......... 6
Break away switch — initial installation................... 6
Initial installation.................................................. 6-7
Test for proper operation................................. 11-12
Wiring diagram....................................................... 7
Combined brake and turn signal
lights — definition (Figure 13)................................ 13
Motorhome monitor wiring —
Initial installation................................................... 10
Test for proper operation...................................... 11
Pedal clamp —
Attaching to brake pedal........................................ 3
Tabs, adjusting....................................................... 3
Power brakes — releasing vacuum —
cautionary statement............................................ 11
Safety definitions...............................inside front cover
Seat adaptor brackets —
determine if bracket is required.......................... 1, 3
Separate brake and turn signal
lights — definition (Figure 13)................................ 13
Stop light switch kits —
determine if stop light switch is required................ 1
Test the system................................................... 11-12
Vacuum, power brakes —
cautionary statement............................................ 11
Weather covers....................................................... 8, 9
19
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V
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ery few people would say they bought their
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vehicle rolls from side to side, especially during cornerof sight and out of mind — even though your driving
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Do you need a custom suspension component?
Each of these components will protect your vehicle
Every “yes” to the following questions is a “yes” for an
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• Does the vehicle “roll” when cornering?
and protect your family (better driving control, reduced
• Does driving for an extended period of time leave you
driver fatigue, more control in evasive maneuvers and
physically exhausted?
• Is your rig all over the road — can’t keep it between
improved driver confidence).
the lines?
Every ROADMASTER suspension component…
• Would you lose control if one of the front tires blew
• …is designed as a custom fit, for a specific chassis.
out?
ROADMASTER engineering designs take into consid• Does the steering wheel have a mind of its own?
eration chassis and axle manufacturers’ specifications
• Do passing 18-wheelers and crosswinds rock your
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• Is driving a ‘white knuckle’ experience?
continued on next page
Suspension Product
Benefit Comparison
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.
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We’re the suspension experts
continued from preceding page
Which component is right for you?
ROADMASTER designs, engineers and manufactures
anti-sway bars, trac bars and steering stabilizers for both
original equipment manufacturers and the aftermarket.
Anti-sway bars, trac bars and steering stabilizers work
in concert with the other components of your suspension
system to add stability and control.
Each of these components has a specific role to play.
The graph on the previous page identifies the primary
benefits of aftermarket suspension products. Each one
has value — for a specific application. It’s important to
understand and identify what you’re experiencing so you
can select the correct product solution.
RSS Anti-Sway Bars
A remarkable improvement in stability and cornering
control — for motorhomes or any large vehicle,
especially towing combinations — is just a few bolts
away. Anti-sway bars from Roadmaster Suspension
Solutions deliver a “Wow!” difference in RV control
you’ll notice the first time you turn the wheel.
• 20 years of experience in the RV industry
• for motorhomes, trucks, vans and SUVs
• more than 100 kits, each one custom-designed for
a specific chassis and suspension system
• large diameter, zinc-plated 4140 chromoly
steel bars, with heavy-duty polyurethane bush ings
• easy installation — in most cases, eight bolts
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 experience the benefit of this product.”
— Johnny Singleton, Myrtle Beach, South Carolina
RSS
stock
A high-grade alloy and a better pivot point — The
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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.
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Reflex Steering Stabilizers
Your best insurance against the catastrophic consequences of a front tire blow out is a Reflex Steering Stabilizer.
When you blow out a front tire, your vehicle will
make an abrupt turn toward that tire, causing you to
veer into oncoming traffic or off the road. The Reflex
Steering Stabilizer’s tempered steel springs, which
are attached to the tie rods and undercarriage, automatically compensate for oversteer caused by front
tire blow outs, pot holes, rut tracks and other unfavorable road conditions, as well as crosswinds and
passing 18-wheelers.
The springs react instantaneously to bring the vehicle back to center.
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
Does your motorhome vibrate from side to side?
Are “wandering,” “rut tracking” and “lazy steering”
a problem? Tired and fatigued trying to keep in line
going down the road?
Davis TruTrac bars link the chassis to the front
axle, eliminating excessive axle side play, without
affecting normal up-and-down suspension travel.
The result is precise, predictable handling. The
benefits are an immediate improvement in both vehicle performance and safety, as well as increased
driver comfort — more positive control means less
driver fatigue.
What do our customers say?
“My F53 chassis would vibrate so bad that it shook
the whole motorhome. The only way to stop the vibration 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 immediately. 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
“We get your towed car there,
while stopping safely along the way.”
All illustrations and specifications contained herein are
based on the latest information available at the time of publication. ROADMASTER, Inc. reserves the right to make
changes, at any time, without notice, in material, specifications and models, or to discontinue models.
Towing and Suspension Solutions
ROADMASTER, Inc. • 6110 NE 127th Ave. • Vancouver, WA 98682
• 800-669-9690 • Fax 360-735-9300 • roadmasterinc.com
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