Hopkins BB006 Remote Control Device User Manual

Download:
Mirror Download [FCC.gov]
Document ID	2292883
Application ID	0wDpY1If5bD0cKk6jXeeaQ==
Document Description	Users Manual
Short Term Confidential	No
Permanent Confidential	No
Supercede	No
Document Type	User Manual
Display Format	Adobe Acrobat PDF - pdf
Filesize	42.78kB (534763 bits)
Date Submitted	2014-06-12 00:00:00
Date Available	2014-06-12 00:00:00
Creation Date	2014-06-06 15:48:51
Producing Software	Adobe PDF Library 11.0
Document Lastmod	2014-06-06 15:48:57
Document Title	Users Manual
Document Creator	Adobe InDesign CC (Macintosh)

Phone (800) 470-2287
Brakebuddy.com
Dedicated to towing safety
TM
TABLE OF CONTENTS
Congratulations on the purchase of your new BrakeBuddy®! The BrakeBuddy® was designed and built as an
auxiliary 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 your
vehicle, serious injury or death. You must read and understand these instructions prior to the use of this
product.
If you have any questions after reading these instructions, please call BrakeBuddy® customer service at 1 800-470-2287.
CONTENTS
Break Away Initial Installation................................................................................... Page
Setup......................................................................................................................... Page
Alert System.............................................................................................................. Page
Operation Instructions............................................................................................... Page
Removal Instructions................................................................................................. Page
Troubleshooting........................................................................................................ Page
Warranty.................................................................................................................... Page
Remove the BrakeBuddy® and components from the shipping carton. The complete system consists of:
Main BrakeBuddy® Unit
Clevis Assembly
Handle and Knob
Remote Alert System
Break-Away System
Air Cylinder Arm
12 Volt DC Cord
Control Panel
Clevis
Handle
Remote Alert
Transmitter
Break-Away Contents
(A) 1, 1/16” coiled breakaway cable with one large
and one small clip on the
ends
(B) 1 junction box with wiring
harness
(C) 1 strap clamp
(D) 2 hex socket head
capscrews
(E) 2 flat washers
(F) 2 lock washers
(G) 2 sheet metal screws
(H) 2 grommets
(I) 5 nylon ties
(J) 1 loose velcro patch
Breakaway System Components
Main Unit Components
311-0288-062 Rev. D 6/14
© 2008 Hopkins Manufacturing Corporation
Pg. 1
Phone (800) 470-2287
Brakebuddy.com
Dedicated to towing safety
TM
BREAK-AWAY INSTALLATION
The Break-Away is an important part of the
BrakeBuddy system and is required
by law in most states. Do not operate
your BrakeBuddy without a properly
functioning Break-Away.
FIG. 2
Installing Junction Box
1. Find a convenient, sturdy place on the
front of your towed vehicle to mount
the junction box (B). This should be
installed on the driver’s side of the
vehicle if possible.
2. Clean the mounting surface and
attach the velcro patch (J) (Fig. 2).
3. Attach the junction box (B) to the
velcro patch (J) so the pin with the
ring faces forward and the wiring
harness feeds back into the engine
compartment.
FIG. 3
4. Place the mounting bracket (C) over
the junction box (B) and mark the hole
locations to be drilled and tapped.
5. Remove bracket (C) and junction box (B). Drill
marked holes with a1/8” metal drill bit.
NOTE: For thin sheet metal or plastic, it may be
necessary to reinforce the plastic or thin metal to
ensure the bracket will not separate from the vehicle
when the break-away pin is pulled. If you are going
to drill through thicker metal, use hex socket head
capscrews (D). You will need to drill a hole using a
#25 drill bit and tap the hole using a 10-24 tap.
FIG. 4
6. Replace the junction box (B) and attach the
bracket (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 the
wiring harness to be fed through into the drivers’
side compartment of the towed vehicle. Use of
an 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 functional
components of the vehicle.
9. Starting from the junction box (Fig. 4 / B),
route the black electrical wire up to the firewall
311-0288-062 Rev. D 6/14
© 2008 Hopkins Manufacturing Corporation
Pg. 2
Phone (800) 470-2287
Brakebuddy.com
Dedicated to towing safety
TM
BREAK-AWAY INSTALLATION
keeping it away from hot or moving engine
components. Secure using the nylon ties (I)
provided (Fig. 4 / M).
FIG. 5
FIG. 6
10. Feed the black wire through the hole in the
firewall and into the passenger compartment
(Fig. 5).
11. Place the split rubber grommet provided (H)
over the black electrical wire (Fig. 6) and
slide it into the 15/32” hole and fasten it into
place (Fig. 7).
NOTE: Failure to properly install the 15/32”
rubber grommet may result in harmful fumes
entering the vehicle, or damage to the wires.
Using the Break-Away System
After attaching your towed vehicle to your coach
and all hook-ups are complete, you will need to
attach the break-away cable (A) from the junction
box (B) to the motorhome. On the motorhome
end attach to a permanent location. The
frame of the vehicle is recommended.
DO NOT attach or wrap the cable around the
tow bar, hitch or bumper.
1. Attach the small clip on the cable (A) to the
loop on the pull pin of the junction box (Fig.
8 / O), and then attach the large clip to the
motorhome (Fig. 8 / P). The coiled breakaway cable fits all applications and needs no
adjustment.
FIG. 7
FIG. 8
2. Setup the BrakeBuddy in your towed vehicle
and plug the junction box wire harness into
the receptacles on top of the BrakeBuddy (Fig.
9 / Q).
3. Before the start of every trip, pull the breakaway pin to test that the break-away system
activates the Brake Buddy.
FIG. 9
4. When the use of the towed vehicle is needed,
simply unhook the small clip from the loop
on the pull pin of the junction box (B).
Unplug the junction box wire harness from
the BrakeBuddy and coil the wire under the
dashboard or under your floor mat (Fig. 10).
311-0288-062 Rev. D 6/14
© 2008 Hopkins Manufacturing Corporation
FIG. 10
Pg. 3
Phone (800) 470-2287
Brakebuddy.com
Dedicated to towing safety
TM
SETUP
1. Press the “Drain” button (A) to ensure there is no air
pressure inside the unit (Figure 1).
2. Attach the lock nut and clevis assembly to the air
cylinder (Fig. 2).
FIG. 1
FIG. 2
Break-Away
Alert System
3. Attach handle assembly to main unit (Fig. 3) with
adjustment knob.
Test
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’s brake
pedal (Fig. 4). Angle the brake pedal clevis so the
upper portion of the clevis grabs the top of the
towed vehicle’s brake pedal. Pull down on the lower
portion of the clevis to extend the clevis under the bottom
of the towed vehicle’s brake pedal. Pull back very firmly on
the red tab (B) until it locks into place securely. If attached
correctly the clevis should be locked securely around the
vehicle’s brake pedal.
FIG. 3
install handle
assembly
Drain
Move seat back.
6. Move the BrakeBuddy® forward until the Air Cylinder Arm is
fully retracted (Fig. 5). Make sure the vehicle’s brake pedal is
not being pressed.
7. Adjust the driver’s seat forward until it is less than a quarter
inch away from the BrakeBuddy’s® handle or loosely touching
the handle (Fig. 6). Again, make sure the vehicle’s brake pedal
is not being pressed.
8. Power the BrakeBuddy® by plugging the unit into a 12-volt
receptacle in the towed vehicle (Fig. 8). When powered, the air
compressor will fill the air tank in under 1 minute. While the air
compressor is filling, the red sensitivity lights will descend from
7 to 1. If a 12-volt power supply is not available in the towed
position (or the 12-volt power remains off in the ignition off
position), a 12-volt Battery Direct Kit is available (part number
39305). At a minimum, a 15-amp 12-volt power supply is
required to operate the BrakeBuddy®.
FIG. 5
Move BrakeBuddy® forward.
FIG. 6
Move seat forward.
9. When the air compressor is completely filled, the red sensitivity
lights will display 1 through 5. This is signaling you to press the
Test button five times to (a) make sure the unit is performing
and adjusted properly; and (b) to remove the vacuum stored
in the towed vehicle’s brake vacuum reservoir, also known as
relieving vacuum.
311-0288-062 Rev. D 6/14
© 2008 Hopkins Manufacturing Corporation
Pg. 4
Phone (800) 470-2287
Brakebuddy.com
Dedicated to towing safety
TM
SETUP
10. Press the Test button on the top BrakeBuddy® panel. The Test
button (Fig. 9 / C) will activate the arm one time. Use this time to
confirm that the unit is in the correct floor position.
Plug into 12v
accessory
receptacle.
FIG. 7
11. If needed adjust the BrakeBuddy® handle (Fig. 8). Loosen the
adjustment knob on the back center portion of the BrakeBuddy®
and adjust the height of the handle so it contacts the seat at the
lowest position possible without sliding under the seat. (NOTE: the
lower on the seat, the firmer the support). Tighten the adjustment
knob to secure handle. Repeat step 7 until the seat is in the
correct position.
12. After pressing the Test button the red sensitivity light will descend
from 5 to 4. When the seat is in the correct position press the Test
button four more times to completely relieve the brake vacuum.
(Make sure the BrakeBuddy® arm is pumping the brake when you
activate the Test button.) Each time the test button is pressed the
red sensitivity light will decrease by an increment of one.
Adjust handle
up or down to fit
seat at lowest
point.
FIG. 8
After pressing the test button five times the sensitivity lights will
change to green indicating that the BrakeBuddy® has relieved the
vacuum of For
the towed
vehicle’s
brakes.
WARNING:
vehicles
equipped
with electric power assist
brakes, call BrakeBuddy® for further instructions 1-800-47013. If needed, make final seat adjustments. You may continue to press
2287. (Electric power assist brakes are common on hybrid
the Test button as many times as ®needed to confirm that the
vehicles; please
call BrakeBuddy if you have questions).
BrakeBuddy® unit is placed in the correct position.
Do
not tow yourLook
vehicle
until
the sensitivity
lights
green.
IMPORTANT:
at the
brake
lights at the
rearare
of the
towed
vehicle to make sure they are not on. If the brake lights are
on, 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 the
system to function properly and may result in damage. Please be
sure a carpet floor mat is being used.
FIG. 9
Break-Away
Alert System
Test
Drain
WARNING: Any time the towed vehicle’s engine has been
started you must push the Test button 5 times after shutting
the towed vehicle’s engine off. This removes the vacuum out of
the vehicle’s brake system. Failure to drain the towed vehicle’s
brake vacuum will result in excessive tire wear.
311-0288-062 Rev. D 6/14
© 2008 Hopkins Manufacturing Corporation
Pg. 5
Phone (800) 470-2287
Brakebuddy.com
Dedicated to towing safety
TM
ALERT SYSTEM INSTALLATION
The Alert System is a wireless monitor that illuminates on your motorhome’s dashboard when the BrakeBuddy is activated
telling you that the BrakeBuddy is working properly. This system consists of two parts, the Transmitter and the Receiver.
The Alert System Receiver (Fig. 10 / A) plugs into a 12-volt
outlet on the dash of the motorhome. When the BrakeBuddy® is
activated in the towed vehicle, the Receiver will illuminate.
The receiver will continually flash red if the towed vehicle’s
battery drops below 10 volts. Also, the BrakeBuddy® main
unit Sensitivity Settings #7, will flash red in a low battery
circumstance. At this time you need to stop and restart your
towed vehicle to recharge the battery. Remember, always
relieve the brake vacuum after shutting the towed vehicle’s
engine off.
FIG. 10
If the towed vehicle breaks away from the motorhome the
receiver gives an audible signal and flashes red. The audible
will sound until the break-away pin is reinserted.
FIG. 11
White
Drain
Black
Test
Alert System
Break-Away
The Transmitter (Fig. 11 / B) plugs
into the top of the BrakeBuddy® and
sends a signal to the Receiver when
the BrakeBuddy® is activated. Plug the
transmitter into the connections on the
BrakeBuddy® marked “Alert System”
(Fig. 2). The antenna should point
toward the motorhome.
Test Procedure
Perform 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, the Receiver 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. Call BrakeBuddy® customer
service, 1-800-470-2287.
FCC/ID Notice: This device complies with Part 15 of FCC Rules and with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following
two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may
cause undesired operation. Unauthorized modification to device could void the user’s authority to operate the equipment.
Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux appareils radio exempts de licence. L’exploitation est autorisée aux deux conditions
suivantes : (1) l’appareil ne doit pas produire de brouillage, et (2) l’utilisateur de l’appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage
est susceptible d’en compromettre le fonctionnement.
311-0288-062 Rev. D 6/14
© 2008 Hopkins Manufacturing Corporation
Pg. 6
Phone (800) 470-2287
Brakebuddy.com
Dedicated to towing safety
TM
OPERATION INSTRUCTIONS
1. Adjust the air regulator knob to match the weight of your
FIG. 12
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.
Break-Away
Alert System
Test
Sensitivity
Button
When the BrakeBuddy® engages, the towed vehicle should give
a slight and smooth tug on the motorhome. Note: Larger
Digital
motorhomes may not feel a tug when towing smaller vehicles.
As mentioned previously, the wireless Alert System also confirms whenDisplay
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 on
your previous trip.
NOTE: Your RV must be moving faster than 15 mph for the
BrakeBuddy to engage the brakes in the towed vehicle.
Air
Regulator
Knob
REMOVAL INSTRUCTIONS
To remove the BrakeBuddy from your towed vehicle, unplug the
unit, push the drain button to relieve the air pressure 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 before handling may
cause damage to your vehicle, serious injury or death.
Drain
VEHICLE WEIGHT FORMULA
Settings are made by adjusting the air
regulator knob. Lift up and turn the knob
clockwise to increase pressure and
counter-clockwise to decrease pressure.
Pounds
1,500 – 2,000
2,000 – 2,500
2,500 – 3,000
3,000 – 3,500
3,500 – 4,000
4,000 – 4,500
4,500 – 5,000
5,000 +
Psi.
With Tow
Dolly
25
35
40
45
50
55
35
45
50
55
60
65
2,041 – 2,268 65
2,268 +		 75
75
85
Kilograms
680 – 907
907 – 1,134
1,134 – 1,361
1,361 – 1,588
1,588 – 1,814
1,814 – 2,041
1999+ Jeep Gr. Cherokee
NOTE: 1999 and newer Jeep Grand
Cherokees should be set at 55 psi.
311-0288-062 Rev. D 6/14
© 2008 Hopkins Manufacturing Corporation
Pg. 7
Phone (800) 470-2287
Brakebuddy.com
Dedicated to towing safety
TM
TROUBLESHOOTING
TROUBLESHOOTING
Problem:
Solution:
The air compressor will not come on after I plug in the BrakeBuddy.
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:
Solution:
The BrakeBuddy will not apply the brakes in the towed vehicle.
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:
Solution:
The BrakeBuddy applies the brakes too hard in my towed vehicle.
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:
Solution:
The BrakeBuddy applies the brake as soon as I plug it in.
Check that the break-away system is properly connected and the 			
pin is plugged into the junction box.
Problem:
Solution:
The compressor pumps up and then keeps on pumping slowly.
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:
Solution:
I have to apply the brakes in my motorhome very hard for the Brake 		
Buddy to come on.
Increase the sensitivity of the BrakeBuddy by pressing the
sensitivity button.
Problem:
Solution:
The BrakeBuddy turns my brake lights on even though I am not 			
applying the brakes in my motorhome.
The BrakeBuddy may be too close to the brake pedal thereby
activating the brake lights. See steps 6 - 12 of the setup
instructions.
Problem:
Solution:
The compressor will not start.
BrakeBuddy is designed with an automatic shut-off on the compressor
when voltage drops to 9.5 volts.
Problem:
Solution:
The seventh sensitivity light is flashing red.
If your towed vehicle’s battery is significantly low the seventh light on the
sensitivity setting will warn you by flashing red. The Brakebuddy System		
will not operate if the towed vehicle’s battery in considerably low.
Problem:
Solution:
I’m experiencing frequent battery drain on my towed vehicle.
Battery drain can depend on your braking style and vehicle type. We recommend
recharging the car battery once every three days to maintain optimum battery
condition. Another solution is to install the Towed Vehicle Battery Maintainer
(#39332). This accessory item continuously maintains the towed vehicle’s battery
charge. Contact your local dealer or BrakeBuddy to order.
311-0288-062 Rev. D 6/14
© 2008 Hopkins Manufacturing Corporation
Pg. 8
Phone (800) 470-2287
Brakebuddy.com
Dedicated to towing safety
TM
WARRANTY
Hopkins Manufacturing Corporation thanks you for purchasing BrakeBuddy.
A 3-year limited warranty and a 30-day money back guarantee apply to your
BrakeBuddy and BrakeBuddy accessories. An additional 2-year extended
warranty is also available (part number 39307). Call BrakeBuddy customer
service at 1-800-470-2287. We wish you safe and happy travels.
LIMITED THREE-YEAR WARRANTY
WHAT 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 from
the 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 BrakeBuddy
customer 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 expressed
or 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.
311-0288-062 Rev. D 6/14
© 2008 Hopkins Manufacturing Corporation
Pg. 9

---

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.5
Linearized                      : Yes
XMP Toolkit                     : Adobe XMP Core 5.5-c021 79.154911, 2013/10/29-11:47:16
Create Date                     : 2014:06:06 15:48:51-05:00
Metadata Date                   : 2014:06:06 15:48:57-05:00
Modify Date                     : 2014:06:06 15:48:57-05:00
Creator Tool                    : Adobe InDesign CC (Macintosh)
Instance ID                     : uuid:1bd4b196-eebd-3a47-848d-cf71d2d1487c
Original Document ID            : xmp.did:F77F1174072068118F62B850E01F8CDD
Document ID                     : xmp.id:b14e54df-9405-4ad0-96d1-61044c053401
Rendition Class                 : proof:pdf
History Action                  : converted
History Parameters              : from application/x-indesign to application/pdf
History Software Agent          : Adobe InDesign CC (Macintosh)
History Changed                 : /
History When                    : 2014:06:06 15:48:51-05:00
Derived From Instance ID        : xmp.iid:af8158fc-03f9-45eb-b5c8-acdb5c8fcedd
Derived From Document ID        : xmp.did:F77F1174072068118F62B850E01F8CDD
Derived From Original Document ID: xmp.did:F77F1174072068118F62B850E01F8CDD
Derived From Rendition Class    : default
Format                          : application/pdf
Producer                        : Adobe PDF Library 11.0
Trapped                         : False
Page Count                      : 9
Creator                         : Adobe InDesign CC (Macintosh)

EXIF Metadata provided by EXIF.tools