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Roadmaster BrakeMaster 9000 User Manual

Roadmaster BrakeMaster 9000
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BrakeMaster 9000 and 9060
Second Motorhome Kit
part number 98300
Installation Instructions
Time Tested • Time Proven
ROADMASTER, Inc. 6110 N.E. 127th Ave. Vancouver, WA 98682
800-669-9690 Fax 360-735-9300 roadmasterinc.com
853811-04 12.17 © 2007-2017 ROADMASTER, Inc. All rights reserved.
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Roadmaster BrakeMaster 9000 Specifications

General IconGeneral
BrandRoadmaster
ModelBrakeMaster 9000
CategoryAutomobile Accessories
LanguageEnglish

Summary

BrakeMaster Second Motorhome Kit Installation Manual

Safety Definitions and Warnings

WARNING: Potential Hazards

Indicates a potentially hazardous situation leading to property damage or injury/death.

CAUTION: Operational Risks

Indicates a potentially hazardous situation leading to property damage or minor/moderate injury.

Pre-Installation Checks and Information

Accessing Vehicle-Specific Data

Check ROADMASTER website for specific installation details for your vehicle.

Adapting to Metric Brake Lines

Using metric-to-standard T-fittings for brake line connections if applicable.

Handling One-Piece Brake Lines

Need for steel brake line if motorhome has one-piece brake line or difficult unions.

Air Compressor Mounting Guidelines

Optimal Mounting Location Selection

Choose a clean, dry area within 20 feet of the starting battery for mounting.

Correct Compressor Orientation

Mount compressor horizontally or vertically with drain valve pointing down.

Air Compressor Wiring: Component Routing

Compressor Positioning and Pre-drilling

Position compressor and drill pilot holes for mounting screws.

Routing Battery and Ignition Wires

Route battery wires and ignition power wire to the compressor.

Air Compressor Wiring: Fuses and Connections

Installing Battery Terminal Fuses

Install 20-amp fuse for red wire and 10-amp fuse for blue wire at battery.

Connecting Power and Ground Wires

Connect red, black, and blue wires to battery and ignition source.

Proportioning Valve Installation: Location

Brake Line Connection Point Selection

Choose location near brake unions or fittings to tee into the brake line.

Motorhome Chassis Mounting Procedure

Mount proportioning valve bracket securely on the motorhome frame.

Proportioning Valve Installation: Preparation

Brake System Vacuum Depletion

Deplete vacuum from the power brake booster before installing the valve.

Master Cylinder Reservoir Fluid Check

Check and fill the master cylinder reservoir with brake fluid to the maximum mark.

Brake Line Disconnection and Plugging

Disconnect brake line from the union, catch fluid, and plug the line.

Proportioning Valve Installation: Connections

Mounting Valve Bracket to Frame

Drill holes and attach the proportioning valve bracket to the frame.

Grounding the Solenoid Valve

Connect a black wire from the solenoid valve to a good chassis ground.

Connecting Brake Tees and Lines

Connect brake tees to factory lines and proportioning valve with supplied brake lines.

Proportioning Valve Installation: Bleeding

Brake Line Kink Warning

Avoid kinking the brake line; a kink can cause brake failure.

Bleeding Air from Proportioning Valve

Loosen the bleeder valve to remove air from the proportioning valve.

Brake Bleeding Procedures

ABS System Brake Bleeding Considerations

Specific procedures for bleeding ABS systems with pressurized bleeders or accumulator.

Specific Brake Line Method

Bleed air from only one wheel cylinder on the proportioning valve line.

Brake Bleeding: Step-by-Step Methods

Specific Brake Line Method Steps

Detailed steps for bleeding using the specific brake line method with an assistant.

Traditional Brake Bleeding Method

Procedure for bleeding all brake lines when air enters the master cylinder.

Brake Bleeding: One-Person Techniques

Vacuum Bleeding Systems

Using vacuum systems to draw air out of the brake lines.

Pressurized Bleeding Systems

Using pressurized systems to push fluid and air out of the brake lines.

Proportioning Valve Wiring to Brake Lights

Identifying Brake Light System Type

Identify brake light system type (separate or combined) for solenoid connection.

Connecting to Motorhome Brake Light Wire

Connect solenoid valve wire to motorhome brake light wire based on system type.

Air Line Installation and Connections

Female Quick Coupler Mounting

Mount female quick coupler at the rear of the motorhome.

Routing and Connecting Air Lines

Route air lines from compressor to proportioning valve and then to coupler.

Air Line Compression Fitting Method

Connect air lines using compression fittings, nuts, ferrules, and brass inserts.

Motorhome Monitor System Installation

Motorhome Wiring for Monitor System

Route wiring from rear of motorhome to dashboard for monitor system.

LED Indicator Installation on Dashboard

Mount and connect the LED indicator on the motorhome dashboard.

Patch Cord Connection Between Vehicles

Connect the patch cord between motorhome and towed vehicle air lines and monitor wires.

Final Connections and System Testing

Connecting Air Compressor Power Source

Connect red and black wires from air compressor to motorhome starting battery.

Verifying System Component Connections

Check that all components are connected and ready for towing.

Air System Leak Check Procedure

Apply leak check solution to all air system joints and fittings to ensure they are airtight.

Final System Tests: Operational Checks

Brake Pedal Operation Verification

Depress and release motorhome brake pedal to check air cylinder extension/retraction.

Monitor LED Functionality Check

Confirm the LED illuminates when the brake pedal is depressed and turns off when released.

Towed Vehicle Lighting System Test

Test towed vehicle brake lights and turn signals operation with motorhome controls.

Troubleshooting: Monitor and Air System Issues

Monitor LED Not Illuminating

Check connections, light braking, fuses, and Brake-Lite Relay for LED issues.

No System Response After Installation

Verify motorhome engine running, air line connections, and solenoid valve wiring.

Troubleshooting: Air Compressor Performance

Compressor Runs Constantly or Frequently

Check for air leaks, closed drain valves, and proper quick coupler function.

Delayed Brake Cylinder Activation

Ensure motorhome engine is running and check air lines for kinks or damage.

Troubleshooting: Towed Vehicle Brake Problems

Abrupt Braking or Tire Flat Spotting

Address abrupt braking or tire issues due to vacuum or active systems.

Towed Vehicle Brake System Adjustments

Adjustments for active braking systems or vehicles without power brakes.

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