Roadmaster BrakeMaster 9100 Installation Instructions Manual
For motorhomes with air or air over hydraulic brakes
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Also See for BrakeMaster 9100:
- Owner's manual (18 pages) ,
- Installation instructions manual (8 pages)
Table of Contents
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Summary of Contents for Roadmaster BrakeMaster 9100
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Page 1: Installation Instructions
BrakeMaster 9100 and 9160 for motorhomes with air or air over hydraulic brakes Installation Instructions Towing and Suspension Solutions ROADMASTER, Inc. • 6110 NE 127th Ave. • Vancouver, WA 98682 • 800-669-9690 • fax 360-735-9300 • roadmasterinc.com... -
Page 2: Table Of Contents
Welcome to the RoADmASteR fAmily! hese instructions have been prepared to acquaint you with the installation of your BrakeMaster, and to provide you with important safety information. Read these instructions, as well as the owner’s manual and all accompanying literature, completely. Understand how to install and operate your BrakeMaster, and carefully follow the instructions and safety precautions. -
Page 3: Before You Begin The Installation (Installer's Checklist)
‘Braking Systems’ and scroll down the page. described on page 3, call the ROADMASTER Technical Service Department at 800-669-9690. 2. if the battery must be disconnected for towing, a stop light switch must be installed. -
Page 5: Install The Air Cylinder Anchor Plate
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 figure 1 steps one through six below… 1. At the towed vehicle, slide the driver’s seat back, as far as it will go. - Page 6 inStAll the AiR cylinDeR AnchoR PlAte following conditions are met: continued from preceding page (Figure 4) attaching the cylinder to the adjustable arm A. Make certain that the pedal clamp is not de- (Figure 4). Slide the air cylinder (Figure 4) up the ad- pressing the towed vehicle’s brake pedal —...
- Page 7 inStAll the AiR cylinDeR AnchoR PlAte 11. Next, attach the anchor plate as shown in Figure continued from preceding page 5, using the provided ¼" x 1" hex head bolts and self- side of the floorboard. 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 Do not drill through any wiring.
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Page 8: Install The Break Away System
Step three connect the wiring Note: if the vehicle’s battery must be disconnected for towing and an automatic battery disconnect has been installed, additional modifications are necessary. If a ROADMASTER Dinghy Battery Manager (part number continued on next page... - Page 9 inStAll the bReAK AWAy SyStem connect the wiring the 10-amp fuse must be within six inches of the positive terminal. if the 10-amp fuse is farther than continued from preceding page six inches, a short circuit may cause significant 765) has been installed, follow the instructions included damage to the towed vehicle’s electrical system, an with the kit.
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Page 10: Install Air Lines In The Towed Vehicle
inStAll AiR lineS in the toWeD vehicle 1. Find a suitable location at the front of the towed 4. Tape the open end of the air line. Then, route the air vehicle to attach the preassembled male quick coupler line from the male quick coupler to the break away air (Figure 10). -
Page 11: Install Air Lines In The Towed Vehicle
inStAll AiR lineS in the toWeD vehicle Note: the quick exhaust valve on the air cylinder continued from preceding page (see page 2) may be rotated, if this provides an easier “hot” components such as the engine or the exhaust connection. -
Page 12: Install The Motorhome Monitor System
inStAll the motoRhome monitoR SyStem Step one Then, remove the vehicle’s brake light fuse, located in the vehicle’s fuse panel. Wire the towed vehicle 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. -
Page 13: Install The Motorhome Monitor System
inStAll the motoRhome monitoR SyStem continued from preceding page figure 15 Step two Wire the motorhome 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... -
Page 14: Install The Motorhome Air Line
inStAll the motoRhome AiR line There are three possible connection points for the brake relay valve (Figure 16), which is typically located motorhome air line — near the master cylinder. There should be one or more open ports with threaded plugs (Figure 16). •... - Page 15 10. Connect the air line to the female quick coupler at the rear of the motorhome. Use the same method ROADMASTER manufactures tees for this pur- described in step 3 under “Install air lines in the towed pose (Figure 18), in ½" (part number 450076) and 3/8"...
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Page 16: System Test
SyStem teSt system with a leak check solution. Always deplete the stored vacuum in the towed vehicle’s power brake system before towing — pump the air system now contains pressurized air, the brake pedal several times. which may cause severe eye or ear injury if it is Depending on the make and model of the towed inadvertently released. -
Page 17: System Test
SyStem teSt continued from preceding page 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 opera- tion of the break away system. To retract the air cylinder and pedal clamp, recon- nect the break away pin. -
Page 18: Brake Light Solutions
If you choose to install a …an optional stop light switch must be installed. system of diodes and rewire the vehicle’s turn signals, ROADMASTER manufactures stop light switch kits for taillights and brake lights for towing, wiring diagrams a number of vehicles; visit www.roadmasterinc.com and are available online, at www.roadmasterinc.com.) -
Page 19: Ford 'Neutral Tow' Vehicles
foRD ‘neUtRAl toW’ vehicleS Some Ford vehicles, such as the Explorer, are 4. Reinstall the brake light fuse, which you removed equipped with a ‘neutral tow’ kit. Use the instructions in step 1. below to wire these vehicles for supplemental braking, 5. -
Page 20: Ford 'Neutral Tow' Vehicles
foRD ‘neUtRAl toW’ vehicleS continued from preceding page cAUtion have separate circuits, a 3-to-2 converter has not been installed. Unless the brake and turn signal diodes are jumped, the towed vehicle’s brake light circuits will 2. First, cut the factory turn signal, taillight and brake ‘override’... -
Page 21: Troubleshooting
tRoUbleShootinG Symptom entire section of air line if any are found. The motorhome monitor LED does not illuminate, 2. Make certain that the air cylinder has been installed even though the brakes in the towed vehicle are being directly in line with the brake pedal. If it is mounted at applied. -
Page 22: Vehicle-Specific Components
The Automatic Battery information. Disconnect also provides: ROADMASTER manufactures stop light switch kits for 1) a constant charged current to the battery while the a number of vehicles; for the most current list, visit the vehicle is being towed, preventing supplemental braking ROADMASTER website at www.roadmasterinc.com and... -
Page 23: Index
inDex ‘Active’ braking systems ..........1 Air cylinder Adjustable arm ............4 Anchor plate Initial installation ..........3-5 Parts list..............2 Air lines Checking for leaks in the system ......14 Connecting to compression fittings......8 Brake lights, towed vehicle Testing for proper operation ........ - Page 24 Towing and Suspension Solutions ROADMASTER, Inc. • 6110 NE 127th Ave. • Vancouver, WA 98682 • 800-669-9690 • fax 360-735-9300 • roadmasterinc.com 851809-10 01/10...
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