Blue Ox BX88161 - Manual (Page 2)

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.us
TM
BRAKESAFE TM is a proportional braking system that can be used on coaches with
Total Air or Air Over Hydraulic braking systems. With BRAKESAFE TM you will use
your coach’s air brakes by tapping into the brake relay air source.
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. There is a right and left brake
actuator hose coming from this relay, these hoses go to the brake actuators of each rear tire of
coach. There is a 3/8” O.D. pilot tubing coming from one of the four ports coming from the
brake relay. This is the SERVICE port that is the preferred place to connect into proportional air
that receives pilot air from the coach’s brake pedal. If this port has a 3/8” hose coming from it,
use the furnished tee fitting. Cut the tubing and push the tubing into each side of the tee fitting,
making sure the tubing is bottomed into the fitting. On the bottom of some relay valves there
are four ports, three are used, the other has a 1/2” pipe plug. Remove this plug and install the
furnished 1/2”pipe to 3/8” tube fitting. If your coach needs a fitting that is not supplied, most
hardware stores have brass pipe fittings. There should be no pressure coming from the port, un-
less the brake pedal is pushed down. If there is, you need to look for another port. Look at Fig.2
for a detailed schematic.
2. For coaches with air over hydraulic braking systems, the air over hydraulic assembly is located
in front of front axle on the driver’s side. There is a drain plug on the bottom side of the air ac-
tuator, take this plug out and use the supplied tube connector. Look at Fig.3 for a detailed sche-
matic.
3/8” Tubing Installation On Coach
3. Push the supplied 3/8” DOT tubing into the tee fitting or the pipe to tube fitting making sure it is
bottomed into the port. Route and secure the 3/8” DOT tubing with the 13” nylon ties supplied
making sure to route away from hot parts. There is 50 ft. of tubing supplied, which should be
plenty for most coaches. Once you get to the rear of the coach with the tubing, secure the mount
bracket with the 1/4” bolts, flat and lockwashers in a convenient location on the bumper. Make
sure it is the one with the larger hole. Then mount the bulkhead fitting, 3/8 tube fitting, and QD
coupler to this mount bracket as shown in Fig.7. Cut the extra 3/8” DOT tubing off and then
push into the pipe to tube fitting.
1/4” Tubing Installation On Towed
4. Unplug the QD plug and 1/4” bulkhead fitting from the self-coil hose assembly. If you have
a Blue Ox baseplate you can use the bracket plate to mount to your baseplate with existing
bolts. Then mount the QD plug and 1/4” bulkhead fitting to this bracket as shown in Fig.7.
If you have a baseplate other than a Blue Ox, you can use the other angle bracket
supplied. Mount this bracket with the 1/4” bolts, flat and lockwashers, and hex nuts to
your baseplate. Then mount the QD plug and 1/4” bulkhead to this bracket. Route the
1/4” tubing through the driver’s side engine compartment using the supplied wire ties,
making sure not to run tubing along hot parts. Push tubing through an existing
grommet through the firewall. If there isn’t a hole, drill a new hole. Continue
routing the tubing behind driver’s side kick panel, then under
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