Bendix Commercial Vehicle Systems DS-2 User Manual

Bendix® SL-5™ Stop Light Switch & Bendix® DS-2™ Combined
Stop Light Switch & Double Check Valve

SD-06-1804

LEAF

SPRING

FULCRUM

CONTACT

STRIP

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DS-2

VALVE

INLET PORT

FIGURE 1 - DS-2™ COMBINED STOP LIGHT SWITCH & DOUBLE CHECK V ALVE SECTIONAL

SHORTING

BAR

OUTLET PORT

DESCRIPTION

TERMINAL

RIVET

PISTON

DIAPHRAGM

SHUTTLE

(CHECK

VALVE)

The stoplight switch is not a serviceable item; and if found
defective in either device, the complete unit must be replaced.

The Bendix® SL-5™ stop light switch is an electro-pneumatic
5 psi non-grounded switch that operates in conjunction with
the brake valve and stop lights by completing the electrical
circuit and lighting the stop lights when a brake application
is made.

The shuttle valve in the DS-2™ valve is serviceable and may
be replaced.

Both the SL-5™ switch and the DS-2™ valve have been tested
and meet the requirements of FMVSS 121.

The DS-2™ combined stop light switch and double check
valve, as the name implies, combines a SL-5™ stop light
switch with a DC-4™ double check valve to perform the
function of both. It operates in conjunction with the brake

OPERATION

The stop switch mechanism is identical in the SL-5™ switch
and the DS-2™ valve.

valve and hand control valve by directing the flow of air from
whichever delivers the higher pressure into a common delivery
line and to the stop light switch, closing the electrical circuit
to the stop lamps.

When a brake application is made, air pressure from the
brake valve enters the cavity below the diaphragm. The air
pressure below the diaphragm moves the piston until it
contacts the leaf spring. The leaf spring travels past a fulcrum

The stop light switch can be used with either 12 or 24 volt
systems.

at which point the leaf springs snaps a shorting bar which
mates with the contact strips. The stop light electrical circuit

VALVE

INLET
PORT

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SL-5
STOP

LIGHT

SWITCH

1

is completed, lighting the stop lights before the brake
application pressures reach 6 psi.

The snap action spring design minimizes arcing.
The double check valve is activated by air being introduced

through either of the two (2) inlet ports. The greater pressure
pushes the shuttle along its guides and closes the opposite
inlet port. The air is then directed out the common delivery
line and to the 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
DS-2™/SL-5™ valve should be inspected every 6 months or
1500 operating hours, whichever comes first, for proper
operation and electrical connections. Should the DS-2™/
SL-5™ valve not meet the elements of the operational tests
noted in this document, further investigation and service of
the valve may be required.

OPERATING AND LEAKAGE TEST

1. Install an accurate air gauge in the service line (or brake
chamber). Apply brake valve gradually . S top lamps should
light at 6 psi or less and go out after the brake application
is released. This checks the electrical function of the
stop light switch in either the SL-5™ switch or DS-2
valve.

2. (DS-2™ valve only) Apply the foot valve and coat the
exhaust port of the hand valve (or other alternate source).
Reverse the above, applying the hand valve or other
alternate source and coat the exhaust port of the foot
valve. In either mode a leakage of not more than a 1”
bubble in 5 seconds is permissible.

3. (SL-5™ switch or DS-2™ valve) When pressurized, no
leakage is permitted from the body of the valve or switch.

If the SL-5™ switch or DS-2™ valve does not function as
described above or if leakage is excessive, the valve or switch
should be replaced with a new unit or in the case of the
double check portion of the DS-2™ valve repaired with genuine
Bendix parts.

REMOVING AND INSTALLING

REMOVING

1. Block vehicle wheels or hold by means other than vehicle
service brakes.

2. Disconnect electrical connections from terminal screws.

3. (SL-5™ switch) Remove the switch using a wrench on
the hex portion of the body .

4. (DS-2™ valve) Disconnect air lines and remove the DS-2
valve.

2

INSTALLING

1. Replace the SL-5™ switch or DS-2™ valve in the port
from which it was removed. Do not install with the
terminals pointing down.

2. Secure electrical connections.

3. Reinstall air line connections to DS-2™ valve.

DISASSEMBL Y (Double Check V alve)

1. Remove three cap screws and cap.

2. Remove o-ring seal from cap.

3. Remove shuttle valve.

CLEANING AND INSPECTION

1. Blow dust or other foreign material out of body . Do not
immerse in cleaning fluid.

2. Inspect shuttle valve and o-rings for excessive wear or
deterioration. Inspect valve seats for nicks or burrs.

Replace all parts that were discarded and any parts not
founds to be serviceable during inspection, using only
genuine Bendix replacement parts.

ASSEMBL Y

Before assembling the DS-2™ double check valve, lubricate
all o-rings and o-ring grooves with Bendix silicone lubricant
(Pc. No. 291 126) or equivalent.

NOTE: When using pipe thread sealant during assembly

and installation, take particular care to prevent the
sealant from entering the valve itself. Apply the
sealant beginning with the second thread back from
the end.

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TEST

Repeat “Operating and Leakage T est”.

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 the

parking brakes, and always block the wheels.
Always wear safety glasses.

2. 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.

3. 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

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all precautions pertaining to use of those tools.