BrakeSafe TM For Coaches w/Total Air or Air Over Hydraulic Brakes OPERATOR, PARTS & INSTALLATION MANUAL BX88143, Pull Cylinder, BrakeSafeTM Blue Ox Division, Automatic Equipment Mfg. Co. • One Mill Road, Industrial Park Pender, Nebraska 68047 • Phone 402-385-3051 • Fax 402-385-3360 • www.blueox.
BX88143 is a proportional braking system that can be used on coaches with Total Air or Air Over Hydraulic braking systems. With the BX88143 you will use your coach’s air brakes by tapping into the brake relay air source. How ever hard you press on the coach’s brakes, is how much the towed vehicle’s brakes will be applied. Locating Air Source On Coach 1. For coaches with total air brake systems, the brake relay is located ahead of the rear axle. This relay has four to five ports, some of which will be used.
Pull-Cylinder Installation Loosen one of the 1 1/4” hex bolts from the mount bracket. The mount bracket will then pivot. Loosen the other 1 1/4” hex bolt enough to get around the brake pedal arm. Place the cylinder assembly on the brake pedal arm about 3/4” above the brake pedal. Tighten both hex bolts equally onto the brake pedal arm making sure the 1/2” band is 90 degrees to the brake pedal pivot axis. Look at Fig. 4 and 5. Make sure the pull cylinder is mounted 90 degrees from brake pedal arm.
INDICATOR LIGHT INSTALLATION The BrakeSafe uses the towed vehicles brakes. Most vehicle’s brake lights work with the key in the off and in the accessory position. This creates the possibility of the towed vehicle’s battery being drained while towing as the brake lights are activated each time the brake pedal is depressed by the BrakeSafe. Included are electrical parts which bypass the towed vehicles battery while towing.
Testing Brake System Connect the towed vehicle to the coach with towing system. Connect the self-coiling air line to the coach and towed vehicle. Make sure the sleeve clicks forward on the QD coupler, this will ensure the plug and coupler are locked. With the towed engine off, pump the brake pedal several times to deplete vacuum or power boost in the towed vehicle’s power brakes.
TOP PORT BRAKE RELAY OPTION 1 A IR SO U RC E LO C AT IO N , C UT T UB E , IN S TA L L T E E FITT IN G PRO POR TIO NA L A IR T O TO W E D B R AK E S YST E M TO R IG HT BR A KE AC TUATO R MA IN AIR IN TO LE F T B RA KE AC T UATO R P R O P R T IO N A L P IL O T A IR NOTE: IT IS IMPORTANT THAT ONLY SERVICE AIR BE TEED INTO. ONLY TEE INTO RELAY VALVE PORTS OR TUBING THAT HAS PRESSURE WHEN COACH BRAKES ARE A PP LIED .
FROM TUBE OR PORT WHEN BRAKE PEDAL IS APPLIED. N O T E : ONLY TAP INTO SERVICE BRAKE AIR. AIR SHOULD FLOW A I R AC T UATO R SUPPLIED TUBE CONNECTOR HYD. MASTERCYLINDER FRONT AIR OVER HYDRAULIC ASSEMBLY IS LOCATED AHEAD OF FRONT AXLE, ON DRIVER’S SIDE MAIN PORT BOTTOM DRAIN PLUG RUN TUBING TO REAR OF COACH AIR SOURCE FOR COACHES WITH AIR OVER HYDRAULIC BRAKES FIG. 3 292-5640 4/06 6 of 12 TM Blue Ox Division, Automatic Equipment Mfg. Co.
PULL CYLINDER MOUNTED TO BRAKE P EDA L VIEWED FROM RIGHT SIDE 1/2” BAND BX88140 & BX88143 PULL CYLINDER MOUNT FIG. 4 SMALL H O LE INSTALL QUICKEXHAUST VALVE IN 1/4” TUBING WITH SMALL HOLE TOWARDS CYLINDER FIR E W ALL S U P P LIE D WASHER & NUT 292-5640 4/06 7 of 12 TM Blue Ox Division, Automatic Equipment Mfg. Co. • One Mill Road, Industrial Park Pender, Nebraska 68047 • Phone 402-385-3051 • Fax 402-385-3360 • www.blueox.
INSTALLATION OF PULL CYLINDER ON BENT BRAKE ARM BAND SHOULD BE VERTICAL AND 90 DEGREES TO PIVOT AXIS INSTRUCTIONS 1. INSTALL PULL CYLINDER BAND L-BRACKET 2. ROTATE CYLINDER HEAD TO VERTICAL L-BRACKET BOLTS. 3. MARK THIS POSITION 4. LOOSEN 5. ROTATE BAND TO THE PROPER POSITION 6. TIGHTEN MOUNT BOLTS PULL CYLINDER FIG. 5 PIVOT AX IS BRAKE ARM 292-5640 4/06 8 of 12 TM Blue Ox Division, Automatic Equipment Mfg. Co.
MOUNT ANGLE BRACKET TO COACH MOUNT BRACKET QD COUPLER (M ALE ) 3/8” BULKHEAD 3/8” TUBE FROM COACH 3/8” TUBE FIT T IN G MOUNT BRACKET PLATE TO BASEPLATE 3/8” SELF-COIL HOSE 1/4” TUBE FROM TOWED FRONT VIEW OF BRACKET PLATE QD PLUG (10-3) 1/4” BULKHEAD QD COUPLER (FE M A LE ) SELF-COIL HOOK-UP FIG. 6 292-5640 4/06 9 of 12 TM Blue Ox Division, Automatic Equipment Mfg. Co. • One Mill Road, Industrial Park Pender, Nebraska 68047 • Phone 402-385-3051 • Fax 402-385-3360 • www.blueox.
Blue Ox Division, Automatic Equipment Mfg. Co. • One Mill Road, Industrial Park Pender, Nebraska 68047 • Phone 402-385-3051 • Fax 402-385-3360 • www.blueox.
Parts List Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 3 3 Part No. Description 293-1346 ............................................................................. Cylinder, Pull, 2 1/8” Bore 293-1345 ................................................................................Piston, Pull, 2 1/8” Bore 293-1303 .....................................................................
BX88143 START-UP CHECKLIST 1. CONNECT TOWED VEHICLE TO THE COACH IN THE NORMAL WAY. IF BREAK-AWAY SYSTEM IS USED, CONNECT LANYARD WIRE BETWEEN COACH AND TOWED VEHICLE. 2. CONNECT THE SELF-COILING AIR LINE TO THE COACH AND TOWED VEHICLE. MAKE SURE THE SLEEVE CLICKS FORWARD ON THE QD COUPLER, THIS WILL ENSURE THE PLUG AND COUPLER ARE LOCKED. 3. MAKE SURE ALL HOSES ARE PLUGGED IN, AND BOTTOMED INTO FITTINGS. BE SURE TO HOOK UP THE BUNGEE CORD FROM THE BRAKE PEDAL TO THE STEERING WHEEL COLUMN.
