Flaming River FR1044 Installation Instructions Manual

Page 1
“The Big Switch” is a durable, heavy duty waterproof disconnect switch. It is designed to complete­ly shut off current flow from the battery of any engine powered vehicle or electrically-powered accessory system. NOTE: When installed with the mounting and lock-out bracket supplied in this kit and physically locked in the “off” position with a padlock (not included), this assembly meets OSHA requirements for positive “lock-out/tag-out” of power for commercial vehicles. “The Big Switch” is rated at 250 amps @ 12V and 24V for continuous service. (2,500 amps for 5 seconds).
The Big Switch Lock-Out Assembly Part No. FR1044 Installation Instructions
WARNING Contact the original manufacturer of the vehicle to determine if this switch is approved for your application and for mounting location. Flaming River Industries, Inc. makes no recommendation as to mounting location or suitability to your application. However, when installed, this switch is a functioning part of the electrical current system. It should be treated as battery terminals.
Terminal Covers are not furnished with this product but are recommend­ed. Flaming River part Number FR1014TM
IMPORTANT NOTE: Please use ONLY an anodized aluminum bracket when installing this switch.
304 Stainless Steel Fasteners
Page 2
Assembly And Installation Instructions NOTE: Before mounting the brackets, install the switch in the mounting bracket as follows:
1. Place the T-handle onto the switch stem and turn to the ON position, then remove the T-handle.
2. Remove the large hex nut and wave washer and the ON/OFF plate from the installation kit package.
3. Insert the neck of the switch into the mounting bracket hole just enough to install the ON/OFF plate, wave washer and start the hex nut.
4. Tighten the brass hex nut until the wave washer is completely flat. (7-10 ft.-lbs.) Do Not Over Tighten! Make sure to align the alignment tab on the switch with the alignment hole on the mounting bracket.
5. Install the T-handle onto the switch stem and turn to the off position. Making sure to align the lock-out hole in the handle with the lock-out hole in the mounting bracket.
6. Remove the spring steel pin from the installation package and tap it in approx 1/4 inch. Ensure that the hole in the handle is aligned with the hole in the switch stem and then finish installing the pin.
Figure 1
Lockout Bracket
Switch Mounting Hole
Locating Tab Hole
Top View
Page 3
Locating Tab
Spring Pin
Spring Pin
Spring Pin Hole
Handle
Handle
Top View
Side View
Figure 2
Electrical Connection Instructions After the switch is mounted, the electrical cables can be attached to the switch. CAUTION: Disconnect the negative cable from the battery before connecting any cables to the switch. The switch will operate effectively by installing it in either the negative or the pos­itive system. However, verify with vehicle manual, and follow all vehicle manufacturers instructions.
1. Select the cable into which the switch will be installed. Disconnect both ends of this cable from its attachment points.
2. It may be necessary to discard this cable and replace it with two (2) separate cables. The length of these cables will equal the length to the switch as shown in Figure 3.
3. Attach the two (2) cable ends to the terminal studs as shown in the illustration in Figure 3. Tighten the hex nuts until the lock washers flatten (11-13 ft. lbs.) Do Not Over Tighten! Make sure the cables on the switch are not touching. Terminal covers are recommended.
4. Connect the other two ends of the cables to their connection points. Reconnect the battery.
Page 4
Figure 3
DO NOT ATTEMPT TO OVER TIGHTEN THE BASE TO THE HOUSING (7-10 FT. LBS Max..) THIS WILL VOID WARRANTY
Battery
Cable
Positive or Negative
Terminal
Cable
Warranty Disclaimer Because of their intended usage, the manufacturer makes no warranties whatsoever expressed or implied, oral or written, to purchasers of their products regarding performance, safety, fit, merchantability or length of service. Purchasers are responsible for selection of proper goods and must rely on their own skill or judgment that such goods are suitable for the purchaser’s application.
1
1
2
2
1
Switch with hardware
Locking bracket
Fastener 1/4-20
Fastener 1/4-20 nuts with lock washers
On/Off Plate
Kit Contains Qty. Description
304 Stainless Steel Fasteners
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