BENDIX BW1593 User's Manual
Contents
1. the parking brakes and always block the wheels Always wear safety glasses Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools If the work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir 10 11 Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle Never exceed manufacturer s recommended pressures Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been deplet2. L 4 switch not meet the elements of the operational tests noted in this document further investigation and service of the valve may be required TESTING FOR SERVICEABILITY OPERATING TEST 1 Apply the brake valve and note that the stop light lights before the delivery pressure reaches 7 psi 2 Release the brake valve and note that the stop light goes off LEAKAGE TEST 1 With the brakes fully applied no leakage is permitted at the stop light switch If the stop light switch does not function as described or if leakage is excessive it is recommended that it be replaced with a new unit or repaired with genuine Bendix parts available at authorized Bendix parts outlets REMOVING 1 Disconnect electrical connections at the stop light switch 2 Disconnect air line to the stop light switch 3 Remove the stop light switch INSTALLING 1 Install in a convenient location for servicing 2 Install with pipe tap pointing to the ground and keep it high for adequate drainage 3 Connect the stop light switch in series in the stop light circuit 4 Keep the stop light switch terminals away from frame members to avoid grounding 5 Connect the pipe tap to the brake chamber supply line so that the stop light switch will operate whether the foot or hand valve is applied DISASSEMBLY SL 3 SWITCH 1 Place hex portion of body in a vise 2 Using alarge end wrench on cover flats turn cover 1 in a counterclockwi
3. ed Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition For vehicles with Antilock Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving BW1593 2006 Bendix Commercial Vehicle Systems LLC All rights reserved 7 2006 Printed in U S A
4. se direction and remove from body 3 Remove terminal nuts terminals 2 and terminal connector 7 from cover 4 Remove spring 3 plunger 4 washer 5 and diaphragm 6 from body SL 4 SWITCH 1 Remove two machine screws 7 and remove cover 8 2 Remove terminal nuts and terminals 9 from cover 3 Remove the vent plug 10 from cover 4 Remove spring 11 contact strip 12 piston 13 and o ring diaphragm 14 from body CLEANING AND INSPECTION Clean all metal parts in cleaning solvent Wipe rubber parts dry with cloth Inspect contact points for pits or wear If pitting is not too severe the points may be reconditioned by filing with a distributor point file If points cannot be reconditioned they should be replaced The contact strip in the SL 4 switch may be turned over to use the other side of the contacts Check the spring for signs of deterioration Replace if discolored The spring in the SL 3 switch carries the current of the electrical circuit involved consequently in the case of excessive current as might be caused by a short the spring will be overheated and ruined Inspect cover and body If cracked or damaged replace Only genuine Bendix service parts should be used for replacement ASSEMBLY SL 3 Switch Figure 1 1 Insert terminal screws 2 in cover 1 making sure the terminal connector 7 is properly positioned 2 Secure terminal screws with washers and n
5. uts or terminal clips as the case may be Place diaphragm 6 in body Position contact plunger 4 on diaphragm Position spring 3 on plunger OP Ol ae Place washer 5 on diaphragm and screw cover 1 into body Torque to 30 foot pounds Make certain the vent hole in the cover is open SL 4 Switch Figure 2 1 Position terminals 9 in cover 8 and secure with washers and nuts or terminal clips Place vent plug 10 in cover 2 Place o ring diaphragm 14 and piston 13 in body O ring diaphragm should be installed with its flat side adjacent to the piston 3 Place gasket 15 in place on body and contact strip 12 on piston 13 4 Position cover assembly on gasket and secure with machine screws Torque to 20 inch pounds TEST OF REBUILT STOP LIGHT SWITCH Both operating and leakage tests as indicated under section headed Testing for Serviceability must be made after rebuilding or repairing the stop light switch The switch must meet the following specifications 1 No leakage is permissible at the stop light switch with the brakes applied 2 The stop light switch contact should close with not more than 7 pounds of air pressure PRECAUTIONARY NOTE WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply
6. y gt i rm COVER 1 a TERMINAL a CONNECTOR 7 sY CONTACTS SPRING 3 WASHER5 PLUNGER 4 DIAPHRAGM6 FIGURE 1 SL 3 STOP LIGHT SWITCH DESCRIPTION The stop light switch is an electro pneumatic switch and operates in conjunction with the brake valve and stop lights by completing the electrical circuit when a brake application is made OPERATION When a brake application is made air pressure from the brake valve enters the cavity below the diaphragm At approximately 5 psi the air pressure underneath the diaphragm overcomes the force of the spring and moves the piston or plunger until the contact points close completing the stop light electrical circuit and lighting the stop lights MACHINE SCREWS 7 CONTACT l PISTON B O RING DIAPHRAGM 14 FIGURE 2 SL 4 STOP LIGHT SWITCH PREVENTIVE MAINTENANCE Important Review the Bendix Warranty Policy before performing any intrusive maintenance procedures A warranty may be voided if intrusive maintenance is performed during the warranty period No two vehicles operate under identical conditions as a result maintenance intervals may vary Experience is a valuable guide in determining the best maintenance interval for air brake system components At a minimum the SL 3 SL 4 switch should be inspected every 6 months or 1500 operating hours whichever comes first for proper operation and electrical connections Should the SL 3 S
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