DUAL CIRCUIT BRAKE SWITCHES AND WARNING LAMP

Since 1967 Volkswagen included a dual circuit brake

81
system in all its vehicles. That means there are two
82a independent hydraulic circuits in the brake system.
This is a safety feature. Should one of the hydraulic
81a BRAKE WARNING circuits fail, the remaining working circuit will allow
LAMP (K7) the driver to stop the car. A warning lamp will
BRAKE LAMP 15
illuminate to notify the driver of the fault so that
SWITCHES (F) FUSE (S2)
61
repairs can be made. When the ignition is switched
VOLTAGE REGULATOR
(TERMINAL 61)
C
on, current flows to terminal 82a of the brake lamp
81a K
82 a
B
switches (F). (There are two brake lamp switches, one
31
FUSE (S2)
E
for each hydraulic circuit.) With the system in good
81 condition, and with the brake pedal at rest, the current
BRAKE LAMPS cannot flow through the switches. When the brake
pedal is depressed both switches are actuated and
contact is made between terminals 82a and 81,
thereby allowing current to flow through the switches and make its way to the brake lamps, which will then be illuminated. However,
if there is a fault in either of the hydraulic circuits, then when the brake pedal is depressed only one of the brake switches will operate,
thereby putting the switches in dissimilar positions. With the switches in an asymmetrical state, current is allowed to find its way to
terminal 81a on one or the other of the switches (depending on which hydraulic circuit is faulty) and finally to the brake warning lamp
which will then illuminate.
The brake warning lamp can be illuminated under two conditions. One is of course when there's a fault in the dual circuit hydraulic
brake system. In this case, when the ignition is in the on position, terminal 15 on the brake warning lamp assembly is energized and
power can pass into the assembly and to the bulb, after which it is interrupted by the transistor. When either of the brake switches
sends a signal from terminal 81a via the red wire to terminal K of the brake warning lamp, the transistor inside (essentially, a relay) is
triggered and allows current to pass from the bulb through the transistor and then to ground, and the bulb illuminates, making the
driver aware of the fault.
The second condition for which the brake warning lamp will light up is for the purpose of a bulb check. This occurs whenever the
ignition is switched on but the motor is not running. In this case, current flows from fuse 2 to terminal 15 of the warning lamp, through
the bulb, past the diode, and out of the lamp via terminal 61. It then continues via the blue wire to the voltage regulator where it finds
ground. When the motor is running, the voltage regulator interrupts the ground connection and the brake warning lamp goes out.

BRAKE SYSTEM WORKING, BRAKE PEDAL AT REST BRAKE SYSTEM FAULTY, FRONT CIRCUIT

81 BRAKE WARNING LAMP 81 BRAKE WARNING LAMP

82a OFF 82a ON

81a 81a
When the switches are
With the switches in in dissimilar positions,
this position, current current is allowed to find
cannot pass through its way to terminal 81a
either of the switches. on one switch or the other,
and then to the warning lamp.
81a 81a
82a 82a

12v FROM FUSE (S2) 12v FROM FUSE (S2)

81 81
TO BRAKE LAMPS TO BRAKE LAMPS

BRAKE SYSTEM WORKING, BRAKE PEDAL DEPRESSED BRAKE SYSTEM FAULTY, REAR CIRCUIT

81 BRAKE WARNING LAMP 81 BRAKE WARNING LAMP

82a OFF 82a ON

81a 81a
With the switches
With the switches in in opposite positions
this position, current from those in the drawing
passes through both above, the current finds
switches to find its a different path to the
way to the brake lamps. brake warning lamp.
81a 81a
82a 82a

12v FROM FUSE (S2) 12v FROM FUSE (S2)

81 81
TO BRAKE LAMPS TO BRAKE LAMPS

BRAKE WARNING LAMP ILLUMINATES, BRAKE FAULT BRAKE WARNING LAMP ILLUMINATES, BULB CHECK

61 B+ 61 B+
FROM 15 FROM 15
FUSE S2 61
FUSE S2 61
C C
K K
B B

D-- FROM 31 D-- FROM 31

82a FUSE E 82a FUSE E

S2 S2
81a 81a
BRAKE WARNING BRAKE WARNING
D+ DF 81a LAMP (K7) D+ DF 81a LAMP (K7)
82a 82a
VOLTAGE VOLTAGE
REGULATOR (C1) REGULATOR (C1)

BRAKE LAMP BRAKE LAMP

SWITCHES (F) SWITCHES (F)

Please report errors to Captain Spalding on theSamba.com 18 September 2018

A tip of the hat to Gary Mondshine and Jim Mais for their indispensable help.