Hopkins BB005 LOW POWER COMMUNICATIONS TRANSMITTER User Manual

Hopkins Manufacturing Corporation LOW POWER COMMUNICATIONS TRANSMITTER Users Manual

Users Manual

TABLE OF CONTENTS311-0288-062 Rev. C 12/08Congratulations on the purchase of your new BrakeBuddy®! The BrakeBuddy®was designed and built as anauxiliary braking system to operate in conjunction with the existing braking system in your towed vehicle.Use of the BrakeBuddy®in a manner inconsistent with these instructions may result in damage to yourvehicle, serious injury or death. You must read and understand these instructions prior to the use of thisproduct. Pg. 1If you have any questions after reading these instructions, please call BrakeBuddy®customer service at 1 800-470-2287.Main Unit Components Breakaway System ComponentsControl PanelAir Cylinder ArmHandle12 Volt DC CordBCDEAFGHIJEDFRemove the BrakeBuddy®and components from the shipping carton. The complete system consists of:Main BrakeBuddy®UnitClevis AssemblyHandle and KnobRemote Alert SystemBreak-Away SystemCONTENTSBreak Away Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 2Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7Removal Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10Break-Away Contents(A)1, 1/16” coiled break-away cable with one largeand one small clip on theends (B) 1 junction box with wiringharness(C) 1 strap clamp (D) 2 hex socket headcapscrews(E)2 flat washers (F)2 lock washers(G)2 sheet metal screws (H) 2 grommets(I) 5 nylon ties(J)1 loose velcro patchClevisDedicated to towing safetyTMPhone (800) 470-2287Brakebuddy.comRemote AlertTransmitter© 2008 Hopkins Manufacturing Corporation
The Break-Away is an important part of theBrakeBuddy system and is required bylaw in most states. Do not operateyour BrakeBuddy without a properlyfunctioning Break-Away.Installing Junction Box1. Find a convenient, sturdy place on thefront of your towed vehicle to mountthe junction box (B). This should beinstalled on the driver’s side of thevehicle if possible. 2. Clean the mounting surface andattach the velcro patch (J)(Fig. 2).3. Attach the junction box (B) to thevelcro patch (J) so the pin with thering faces forward and the wiringharness feeds back into the enginecompartment. 4. Place the mounting bracket (C)overthe junction box (B) and mark thehole locations to be drilled andtapped.5. Remove bracket (C) and junction box (B). Drillmarked holes with a1/8" metal drill bit. NOTE: For thin sheet metal or plastic, it may benecessary to reinforce the plastic or thin metal toensure the bracket will not separate from thevehiclewhen the break-away pin is pulled. If you are goingto drill through thicker metal, use hex socket headcapscrews (D). You will need to drill a hole using a#25 drill bit and tap the hole using a 10-24 tap. 6. Replace the junction box (B) and attach thebracket (C) using hex socket head capscrews(D) or sheet metal screws (G)provided (Fig. 3).7. Locate a place in the firewall that will allow thewiring harness to be fed through into the drivers’side compartment of the towed vehicle. Use ofan existing hole would be most convenient. 8. If there is no existing hole, drill a 15/32"diameter hole through the firewall (Fig. 4 / K).Be careful not to drill into any functionalcomponents of the vehicle.9. Starting from the junction box (Fig. 4 / B), routeFIG. 2FIG. 3BCDGJKMHBBREAK-AWAY INSTALLATIONFIG. 4Dedicated to towing safetyTMPhone (800) 470-2287Brakebuddy.com311-0288-062 Rev. C 12/08 Pg. 2© 2008 Hopkins Manufacturing Corporation
BREAK-AWAY INSTALLATIONDedicated to towing safetyTMPhone (800) 470-2287Brakebuddy.comthe black electrical wire up to the firewallkeeping it away from hot or moving enginecomponents. Secure using the nylon ties (I)provided (Fig. 4 / M).10. Feed the black wire through the hole in thefirewall and into the passenger compartment(Fig. 5).11. Place the split rubber grommet provided (H)over the black electrical wire (Fig. 6) andslide it into the 15/32" hole and fasten it intoplace (Fig. 7). NOTE: Failure to properly install the 15/32"rubber grommet may result in harmful fumesentering the vehicle, or damage to the wires.Using the Break-Away SystemAfter attaching your towed vehicle to your coachand all hook-ups are complete, you will need toattach the break-away cable (A) from the junctionbox (B)to the motorhome. On the motorhomeend attach to a permanent location. The frameof the vehicle is recommended. DO NOTattach or wrap the cable around the tow bar,hitch or bumper.1. Attach the small clip on the cable (A)to theloop on the pull pin of the junction box (Fig. 8 /O), and then attach the large clip to themotorhome (Fig. 8 / P). The coiled break-away cable fits all applications and needs noadjustment.2. Setup the BrakeBuddy in your towed vehicleand plug the junction box wire harness intothe receptacles on top of the BrakeBuddy (Fig.9 / Q). 3. Before the start of every trip, pull the break-away pin to test that the break-away systemactivates the Brake Buddy. 4. When the use of the towed vehicle is needed,simply unhook the small clip from the loop onthe pull pin of the junction box (B). Unplug thejunction box wire harness from theBrakeBuddy and coil the wire under thedashboard or under your floor mat (Fig. 10).FIG. 5 FIG. 6FIG. 7FIG. 8FIG. 9FIG. 10POQ311-0288-062 Rev. C 12/08 Pg. 3© 2008 Hopkins Manufacturing Corporation
Pg. 4FIG. 3FIG. 2Move seat back.FIG. 4BMove BrakeBuddy®forward. Move seat forward.FIG. 5 FIG. 6install handle assembly1. Press the “Drain” button (A)to ensure there is noair pressure inside the unit (Figure 1).2. Attach the lock nut and clevis assembly to the aircylinder (Fig. 2).3. Attach handle assembly to main unit (Fig. 3) withadjustment knob.4. Adjust the driver’s seat to the far back position(Fig. 3). Place the BrakeBuddy®on the floorboard. 5. With the notched end of the clevis facing up,attach the clevis to the top of the towed vehicle’sbrake pedal (Fig. 4). Angle the brake pedal clevisso the upper portion of the clevis grabs the top ofthe towed vehicle’s brake pedal. Pull down on thelower portion of the clevis to extend the clevis under the bottomof the towed vehicle’s brake pedal. Pull back very firmly on thered tab (B) until it locks into place securely. If attached correctlythe clevis should be locked securely around the vehicle’s brakepedal.6. Move the BrakeBuddy®forward until the Air Cylinder Arm isfully retracted (Fig. 5). Make sure the vehicle’s brake pedal isnot being pressed.7. Adjust the driver’s seat forward until it is less than a quarterinch away from the BrakeBuddy’s®handle or loosely touchingthe handle (Fig. 6). Again, make sure the vehicle’s brake pedalis not being pressed.8. Power the BrakeBuddy®by plugging the unit into a 12-voltreceptacle in the towed vehicle (Fig. 8). When powered, the aircompressor will fill the air tank in under 1 minute. While the aircompressor is filling, the red sensitivity lights will descend from7 to 1. If a 12-volt power supply is not available in the towedposition (or the 12-volt power remains off in the ignition offposition), a 12-volt Battery Direct Kit is available (part number39305). At a minimum, a 15-amp 12-volt power supply isrequired to operate the BrakeBuddy®. 9. When the air compressor is completely filled, the red sensitivitylights will display 1 through 5. This is signaling you to press theTest button five times to (a) make sure the unit is performingand adjusted properly; and (b) to remove the vacuum stored inthe towed vehicle’s brake vacuum reservoir, also known asrelieving vacuum.SETUPDedicated to towing safetyTMPhone (800) 470-2287Brakebuddy.com311-0288-062 Rev. C 12/08Alert SystemTestDrainBreak-AwayAFIG. 1© 2008 Hopkins Manufacturing Corporation
311-0288-062 Rev. C 12/08 Pg. 510.Press the Test button on the top BrakeBuddy®panel. The Testbutton (Fig. 9 / C) will activate the arm one time. Use this time toconfirm that the unit is in the correct floor position. 11. If needed adjust the BrakeBuddy®handle (Fig. 8). Loosen theadjustment knob on the back center portion of the BrakeBuddy®and adjust the height of the handle so it contacts the seat at thelowest position possible without sliding under the seat. (NOTE: thelower on the seat, the firmer the support). Tighten the adjustmentknob to secure handle. Repeat step 7 until the seat is in thecorrect position. 12.After pressing the Test button the red sensitivity light will descendfrom 5 to 4. When the seat is in the correct position press the Testbutton four more times to completely relieve the brake vacuum.(Make sure the BrakeBuddy®arm is pumping the brake when youactivate the Test button.) Each time the test button is pressed thered sensitivity light will decrease by an increment of one. After pressing the test button five times the sensitivity lights willchange to green indicating that the BrakeBuddy®has relieved thevacuum of the towed vehicle’s brakes. 13.If needed, make final seat adjustments. You may continue to pressthe Test button as many times as needed to confirm that theBrakeBuddy®unit is placed in the correct position. IMPORTANT:Look at the brake lights at the rear of the towedvehicle to make sure they are not on. If the brake lights areon, the BrakeBuddy®is too close to the brake pedal.If for some reason the BrakeBuddy®does not fit your vehicle properly,please call technical service at 1-800-470-2287.NOTE: A rubber floor mat under the BrakeBuddy®will not allow thesystem to function properly and may result in damage. Please besure a carpet floor mat is being used.WARNING: Any time the towed vehicle’s engine has beenstarted you must push the Test button 5 times after shuttingthe towed vehicle’s engine off. This removes the vacuum out ofthe vehicle’s brake system. Failure to drain the towed vehicle’sbrake vacuum will result in excessive tire wear.FIG. 8 Adjust handleup or down to fitseat at lowestpoint.Alert SystemTestDrainBreak-AwayCFIG. 9FIG. 7Plug into 12vaccessoryreceptacle.SETUPDedicated to towing safetyTMPhone (800) 470-2287Brakebuddy.comDo not tow your vehicle until the sensitivity lights are green.WARNING: For vehicles equipped with electric power assistbrakes, call BrakeBuddy®for further instructions 1-800-470-2287. (Electric power assist brakes are common on hybridvehicles; please call BrakeBuddy®if you have questions).© 2008 Hopkins Manufacturing Corporation
311-0288-062 Rev. C 12/08 Pg. 6ALERT SYSTEM INSTALLATIONThe Alert System is a wireless monitor that illuminates on your motorhome’s dashboard when the BrakeBuddy isactivated telling you that the BrakeBuddy is working properly. This system consists of two parts, the Transmitterand the Receiver.The Alert System Receiver (Fig. 10 / A) plugs into a12-volt outlet on the dash of the motorhome. When theBrakeBuddy®is activated in the towed vehicle, theReceiver will illuminate. The receiver will continually flash red if the towedvehicle’s battery drops below 10 volts. Also, theBrakeBuddy®main unit Sensitivity Settings #7, will flashred in a low battery circumstance. At this time you needto stop and restart your towed vehicle to recharge thebattery. Remember, always relieve the brake vacuumafter shutting the towed vehicle’s engine off. If the towed vehicle breaks away from the motorhomethe receiver gives an audible signal and flashes red. Theaudible will sound until the break-away pin is reinserted. The Transmitter (Fig. 11 / B)plugs into the top of theBrakeBuddy®and sends a signal tothe Receiver when theBrakeBuddy®is activated. Plug thetransmitter into the connections onthe BrakeBuddy®marked “AlertSystem” (Fig. 2). The antennashould point toward themotorhome.FCC/ID Notice: This device complies with Part 15 of FCC Rules. Operation is subject to the following two conditions: (1) This devicemay not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.FIG. 10ATest ProcedurePerform each time before use.Before you begin towing, a simple test should be performed to assure your Alert System is operating properly. Have someone push the red test button on the BrakeBuddy®(Fig. 3 / C) and hold it for ten seconds while you are in your parked motorhome looking at the Receiver. The Receiver should illuminate for the full ten seconds without blinking. Do not do this while the motorhome is moving! The Alert Receiver will illuminate: (1) when the test button is pressed; (2) when the BrakeBuddy activates as a result of forward inertia (i.e., the braking of the motorhome) ; or (3) if the Break-Away pin is pulled. NOTE:In the unlikely circumstance that the receiver is plugged into a 12-volt outlet within 5 feet of the main unit, theReceiver will not confirm braking activity. The BrakeBuddy®Classic will continue to operate the braking function,but the receiver will not glow red to confirm braking. NOTE: An optional transmitter extension cord is available if the signal is not reaching the receiver. CallBrakeBuddy®customer service, 1-800-470-2287.Alert SystemTestDrainBreak-AwayFIG. 11BCWhiteBlackDedicated to towing safetyTMPhone (800) 470-2287Brakebuddy.com© 2008 Hopkins Manufacturing Corporation
1. Adjust the air regulator knob to match the weight of your towed vehicle (Figure 12). The braking pressure, or how hard your towed vehicle will brake in tow, is adjusted by the air regulator on top of the BrakeBuddy®. To find the correct pressure setting for your vehicle, please refer to the Vehicle Weight Formula Chart below. To adjust the setting, pull up on the air regulator knob, turn knob until the pressure gauge reads the correct setting specified by the Vehicle Weight Formula Chart, and push the knob down to lock it in place. Press the red button in the Digital Display to choose your preferred mode of weight measurement of kilograms or Psi.When the BrakeBuddy®engages, the towed vehicle should give a slight and smooth tug on the motorhome. Note: Larger motorhomes may not feel a tug when towing smaller vehicles. As mentioned previously, the wireless Alert System also confirmswhen and how long the BrakeBuddy®is activating.2. Adjust the Sensitivity Button. The Sensitivity Button on the top of the BrakeBuddy®determines how hard you must apply the brakes in the motorhome before the BrakeBuddy will engage the brakes in your towed vehicle. The sensitivity of the BrakeBuddy®is adjusted by holding down the Sensitivity Button (Figure 10). The more lights that are illuminated, the easier the BrakeBuddy will activate. Each time the BrakeBuddy®is installed, the sensitivity will return to the last setting used onyour previous trip. NOTE: Your RV must be moving faster than 15 mph for the BrakeBuddy to engage the brakes in the towed vehicle.Alert SystemTestDrainBreak-AwayOPERATION INSTRUCTIONSFIG. 12VEHICLE WEIGHT FORMULASettings are made by adjusting the air regulator knob. Lift up and turn the knobclockwise to increase pressure and counter-clockwise to decrease pressure.NOTE: 1999 and newer Jeep GrandCherokees should be set at 55 psi.DigitalDisplayAirRegulatorKnobSensitivityButton1,500 – 2,000 680 – 907 25 352,000 – 2,500 907 – 1,134 35 452,500 – 3,000 1,134 – 1,361 40 503,000 – 3,500 1,361 – 1,588 45 553,500 – 4,000 1,588 – 1,814 50 604,000 – 4,500 1,814 – 2,041 55 651999+ Jeep Gr.Cherokee4,500 – 5,000 2,041 – 2,268 65 755,000 + 2,268 + 75 85Pounds Kilograms Psi. With TowDolly311-0288-062 Rev. C 12/08Dedicated to towing safetyTMPhone (800) 470-2287Brakebuddy.com© 2008 Hopkins Manufacturing Corporation Pg. 7
REMOVAL INSTRUCTIONSInformation to User:NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuantto part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmfulinterference in a residential installation. FCC Radiation Exposure Statement to comply with FCC RF exposurerequirements in section 1.1307, a minimum separation distance of 1.40 cm (0.6 inches) is required between theantenna and all persons. This equipment generates, uses and can radiate radio frequency energy and, if notinstalled and used in accordance with the instructions, may cause harmful interference to radio communications.However, there is no guarantee that interference will not occur in a particular installation. If this equipment doescause harmful interference to radio or television reception, which can be determined by turning the equipment offand on, the user is encouraged to try to correct the interference by one or more of the following measures:- Reorient or relocate the receiving antenna.-Increase the separation between the equipment and receiver.-Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.- Consult the dealer or an experienced radio / TV technician for help.CAUTION: Changes or modifications not expressly approved by Hopkins Manufacturing Corporation could voidthe user’s authority to operate the equipment.To remove the BrakeBuddy from your towed vehicle, unplug the unit, push the drain button to relieve the airpressure in the system, adjust seat back and remove the BrakeBuddy.CAUTION: Failure to drain your BrakeBuddy’s air system and unplug it from the car’s power source beforehandling may cause damage to your vehicle, serious injury or death.311-0288-062 Rev. C 12/08 © 2008 Hopkins Manufacturing Corporation Pg. 8Dedicated to towing safetyTMPhone (800) 470-2287Brakebuddy.com
TROUBLESHOOTINGProblem: The air compressor will not come on after I plug in the BrakeBuddy.Solution: Check the air gauge for pressure in the tank. If the tank is already pressurized, the compressor is designed to not come on until the tank’s pressure is reduced by BrakeBuddy activation. Make sure there is power to the 12-volt receptacle and the fuse for the 12-volt plug is functioning. If both are functioning, the green indicator light on the 12-volt plug will be lit when it is plugged in. To remove the fuse on the BrakeBuddy’s power cord, unscrew the finger nut on the end of the plug. Replace fuse with a 15-amp fuse.Problem: The BrakeBuddy will not apply the brakes in the towed vehicle.Solution: Make sure the air regulator is properly adjusted for the weight of the towed vehicle. Also check the sensitivity setting. Remember, your RV must be moving at least 15 mph for the BrakeBuddy to activate.Problem: The BrakeBuddy applies the brakes too hard in my towed vehicle.Solution: Push the test button five times before towing to relieve the vacuum in the towed vehicle’s brake booster. Or adjust the air regulator knob to reduce the air pressure.Problem: The BrakeBuddy applies the brake as soon as I plug it in.Solution: Check that the break-away system is properly connected and the pin is plugged into the junction box. Problem: The compressor pumps up and then keeps on pumping slowly.Solution: There may not be enough current to the BrakeBuddy. You may have a weak battery or you may need a “12-volt Battery Direct Kit”(part number 39305). At a minimum, a 15-amp 12-volt cigarette lighter or auxiliary power plug is required to operate the BrakeBuddy.Problem: I have to apply the brakes in my motorhome very hard for the Brake Buddy to come on.Solution: Increase the sensitivity of the BrakeBuddy by pressing the sensitivity button.Problem: The BrakeBuddy turns my brake lights on even though I am not applying the brakes in my motorhome.Solution: The BrakeBuddy may be too close to the brake pedal thereby activating the brake lights. See steps 6 - 12 of the setup instructions. Problem: The compressor will not start.Solution: BrakeBuddy is designed with an automatic shut-off on the compressor when voltage drops to 9.5 volts.Problem: The seventh sensitivity light is flashing red.Solution: If your towed vehicle’s battery is significantly low the seventh light on the sensitivity setting will warn you by flashing red. The Brakebuddy Systemwill not operate if the towed vehicle’s battery in considerably low.Problem: I’m experiencing frequent battery drain on my towed vehicle.Solution: Battery drain can depend on your braking style and vehicle type. We recommendrecharging the car battery once every three days to maintain optimum batterycondition. Another solution is to install the Towed Vehicle Battery Maintainer(#39332). This accessory item continuously maintains the towed vehicle’s batterycharge. Contact your local dealer or BrakeBuddy to order.TROUBLESHOOTING311-0288-062 Rev. C 12/08Dedicated to towing safetyTMPhone (800) 470-2287Brakebuddy.com© 2008 Hopkins Manufacturing Corporation Pg. 9
Hopkins Manufacturing Corporation thanks you for purchasing BrakeBuddy.A 3-year limited warranty and a 30-day money back guarantee apply to yourBrakeBuddy and BrakeBuddy accessories. An additional 2-year extendedwarranty is also available (part number 39307). Call BrakeBuddy customerservice at 1-800-470-2287. We wish you safe and happy travels.LIMITED THREE-YEAR WARRANTYWHAT IS COVERED AND FOR HOW LONG?We are confident our product will perform well and therefore warrant to you, as the original retail purchaser, for a period of three years fromthe date of original purchase, that your new product will be free of mechanical and electrical defects in material and workmanship.WHAT WILL BRAKEBUDDY DO? HOW DO I GET SERVICE?During the warranty period, we will repair or replace your new product (at our option) without cost to you, which will be your exclusive remedy under this warranty. Please do not return this product to the place of purchase. Doing so may delay the processing of your claim and our repair of your product. Return your product postage prepaid, with proof of purchase. Please call BrakeBuddycustomer service for shipping instructions.WHAT IS NOT COVERED?Our warranty for your product will not cover damage resulting from neglect or misuse of the product, use of improper voltage or current, use contrary to operating instructions, or disassembly, repair, or alteration by any person other than an authorized service station. Any implied warranty of merchantability or fitness for a particular purpose of your product is limited to the duration of this written warranty. We shall not be liable for any incidental or consequential damages for breach of any expressedor implied warranty on your product.HOW YOUR STATE'S LAWS MAY APPLY:Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state.WARRANTY311-0288-062 Rev. C 12/08 © 2008 Hopkins Manufacturing Corporation Pg. 10Dedicated to towing safetyTMPhone (800) 470-2287Brakebuddy.com

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