INSTALLATION

& OPERATION

MANUAL

XS 8000

INTENSITY

TM

STROBE LIGHTBAR

PATENT PENDING

XS8000

INTENSITY

TM

STROBE LIGHTBAR

Contents:

Introduction................................................................................ 2

Unpacking & Pre-Installation ..................................................... 2

Installation & Mounting .............................................................. 3

Hook-on Mounting ................................................................ 3

Permanent Mounting ............................................................ 4

Wiring Instructions .................................................................. 4-9

Options ...................................................................................... 9

Maintenance ......................................................................... 9-11

Troubleshooting .................................................................. 11-14

Electronics Module Removal ................................................... 14

Installing New Filters or Take Down/Work Lights .................... 14

Replacement Parts / Exploded View .................................. 15-17

Warranty .................................................................................. 18

IMPORTANT:

Read all instructions and warnings before installing and using.

INSTALLER: This manual must be delivered to the end user of this equipment.

Introduction

The XS 8000 Strobe Bar is a lightbar that is 4" high, yet delivers unobstructed 360-degree warning and more signal power and versatility than any other lightbar of its size.

The low profile and aerodynamic lines of the "XS" reduce air drag, which results in fuel savings and stability at high speeds. The bar has a strong extruded internal frame, shock-resistant polycarbonate lenses, and warning signals that exceed SAE standards (meets CA XIII).

The "XS" is designed on a modular basis, which means that the lightbar can be customized to meet any requirements. Because of its design, the "XS" has room for an incredible number of options, Directional Strobe units, Halogen Flashers, Halogen Rotators, Halogen Takedown/Work Lights, Intersection Lights, Arrowstik ® ,

Oscilaser ® , Truck Clearance and Stop/Turn/Tail Lights plus Alley Lights.

!

WARNING!

The use of this or any warning device does not insure that all drivers can or will observe or react to an emergency warning signal. Never take the right-of-way for granted. It is your responsibility to be sure you can proceed safely before entering an intersection, driving against traffic, responding at a high rate of speed, or walking on or around traffic lanes.

The effectiveness of this warning device is highly dependent upon correct mounting and wiring.

Read and follow the manufacturer’s instructions before installing or using this device. The vehicle operator should insure daily that all features of the device operate correctly. In use, the vehicle operator should insure the projection of the warning signal is not blocked by vehicle components

(i.e.: open trunks or compartment doors), people, vehicles, or other obstructions.

This equipment is intended for use by authorized personnel only. It is the user’s responsibility to understand and obey all laws regarding emergency warning devices. The user should check all applicable city, state and federal laws and regulations.

Public Safety Equipment, Inc., assumes no liability for any loss resulting from the use of this warning device.

Proper installation is vital to the performance of this warning device and the safe operation of the emergency vehicle. It is important to recognize that the operator of the emergency vehicle is under psychological and physiological stress caused by the emergency situation. The warning device should be installed in such a manner as to: A) Not reduce the output performance of the system, B)

Place the controls within convenient reach of the operator so that he can operate the system without losing eye contact with the roadway.

Emergency warning devices often require high electrical voltages and/or currents. Properly protect and use caution around live electrical connections. Grounding or shorting of electrical connections can cause high current arcing, which can cause personal injury and/or severe vehicle damage, including fire. Do not touch the strobe light tubes, the strobe light head assemblies or the strobe power supply while the system is in operation. Wait 10 minutes after turning off the power from system before touching any internal components.

PROPER INSTALLATION COMBINED WITH OPERATOR TRAINING IN THE PROPER USE OF

EMERGENCY WARNING DEVICES IS ESSENTIAL TO INSURE THE SAFETY OF EMERGENCY

PERSONNEL AND THE PUBLIC.

Unpacking & Pre-installation

Carefully remove the lightbar and place it on a flat surface, taking care not to scratch the lenses or damage the cable coming out of the bottom. Examine the unit for transit damage, broken lamps, etc. Report any damage to the carrier and keep the shipping box.

Standard lightbars are built to operate on 12 volt D.C. negative ground (earth) vehicles. If you have an electrical system other than 12 volt D.C. negative (earth) ground, and have not ordered a specially wired lightbar, contact the factory for instructions.

Test the unit before installation. To test, connect the #10 GA. black wire to NEGATIVE (-) (earth) and touch each wire in the cable to +12 VDC and observe the proper function as described in the wiring section of this manual (an automotive battery is preferable for this test). A battery charger may be used, but please note that some electronic options may not operate normally when powered by a battery charger. If problems occur at this point, contact the factory.

2

Installation & Mounting

Hook-on Mounting

The vehicle on which the lightbar is being mounted should be parked upon level ground.

Begin the installation by attaching the rubber feet to the mounting brackets using the short 1/4" bolts and acorn nuts provided. (See Figure 1; do not install shims at this time).

Loosely attach the mounting brackets to the underside of the lightbar using the 5/16-18 x

5/8 carriage bolts, 5/16" split lock washers and 5/16" nuts provided. Place the bar on the vehicle roof and adjust the position of the mounting brackets to the roof edge while keeping the bar centered side to side. Now attempt to locate a position in which the bar is level front to back. If leveling is required, install the shim washers at this time. (See Figure 1) If additional leveling is still needed, contact the factory for assistance.

Lift each end of the lightbar and insert the 5/16-18 x 2-1/2" hex bolt from the back side. (See Figure 1). Install the gutter hooks, lock washers and trim nuts and tighten until secure. DO NOT OVERTIGHTEN: It is not necessary to dimple the roof in order to achieve a secure and stable mount.

Figure 1

Figure 2

When the brackets are tightened to the lightbar the rubber feet should rest as close to the edge of the roof as possible (see Figure 2).

The tabs holding the rubber feet may be bent to conform to the roof profile as shown in Figure 4.

NOTE: Some vehicles may require a slightly longer or shorter mounting bolt. These are stainless steel 5/16" coarse thread bolts which can be obtained locally.

Figure 3

3

Permanent Mounting

The vehicle on which the lightbar is being mounted should be parked upon level ground.

Examine the roof of the vehicle to determine the areas of greatest strength as well as location of air horns, etc.

that will affect the location of the lightbar. Attach the mounting brackets to the underside of the lightbar, using the 5/16-18 x 5/8" carriage bolts, 5/16" split lock washers, and 5/16" nuts provided.

Attempt to locate a position in which the bar is level front and back. If leveling is required, slide the shim washer under the appropriate tabs on the mounting brackets. (See Figure 3). If additional leveling is still needed, contact the factory for assistance.

Once the bar is level front to rear and centered side to side, mark the holes through the mounting tabs and remove the bar from the vehicle. Drill out the mounting holes and remove any burrs. Attach the die cut rubber brackets or shims, if used. (See Figure 3). Remount the lightbar and attach to roof using four suitable fasteners obtained locally.

NOTE: The tabs on the mounting brackets may be bent at any angle to match the curvature of the roof. (See

Figure 4).

Figure 4

Wiring Instructions

!

WARNING!

Larger wires and tight connections will provide longer service life for components. For high current wires it is highly recommended that terminal blocks or soldered connections be used with shrink tubing to protect the connections. Do not use insulation displacement connectors

(e.g. 3M ® Scotchlock type connectors). Route wiring using grommets and sealant when passing through compartment walls. Minimize the number of splices to reduce voltage drop.

High ambient temperatures (e.g. underhood) will significantly reduce the current carrying capacity of wires, fuses, and circuit breakers. Use "SXL" type wire in engine compartment.

All wiring would conform to the minimum wire size and other recommendations of the manufacturer and be protected from moving parts and hot surfaces. Looms, grommets, cable ties, and similar installation hardware should be used to anchor and protect all wiring.

Fuses or circuit breakers should be located as close to the power takeoff points as possible and properly sized to protect the wiring and devices.

Particular attention should be paid to the location and method of making electrical connections and splices to protect these points from corrosion and loss of conductivity. Ground terminations should only be made to substantial chassis components, preferably directly to the vehicle battery.

The user should install a fuse sized to approximately 125% of the maximum Amp capacity in the supply line to protect against short circuits. For example, a 30 Amp fuse should carry a maximum of 24 Amps. DO NOT USE 1/4" DIAMETER GLASS FUSES AS THEY ARE NOT

SUITABLE FOR CONTINUOUS DUTY IN SIZES ABOVE 15 AMPS. Circuit breakers are very sensitive to high temperatures and will "false trip" when mounted in hot environments or operated close to their capacity.

!

WARNING!

Any electronic device may create or be affected by electromagnetic interference. After installation of any electronic device, operate all equipment simultaneously to insure that operation is free of interference.

4

POWER CONNECTIONS:

Connect the BLACK #10 GA. wire to the vehicle's NEGATIVE (-) (earth) battery terminal.

INDIVIDUAL LIGHTBAR FUNCTION CONNECTIONS

NOTE : correct hookup of your lightbar.

Route the multicolored control cable(s) exiting the lightbar into the vehicle's passenger compartment to the location of the control switch box to be used for operation of the lightbar. Plug any holes made in the vehicle's exterior with sealant to prevent leaks.

Run a power wire from the control switch box to the POSITIVE (+) battery terminal using a #10 GA. minimum wire. Use of a 40 amp circuit breaker, PSE P/N T02838, is recommended to protect the lightbar and vehicle in the event of a short circuit.

STROBE LIGHTING CONNECTIONS

Flash Patterns: All flash patterns are available in either "Quad Flash" or "Random Flash" modes. The mode selection is controlled by jumper J31 on the power supply and can be changed by first removing the power supply from the lightbar and then moving J31. If the lightbar contains two power supplies, the jumpers on each power supply must be changed.

Rear Only Flash Pattern

Connect the RED wire in the 14 wire cable to +12VDC through a user supplied switch.

4 - HEAD - Rear inboard and outboard strobes on each side will flash at a minimum rate of 70 flashes per minute.

2 - HEAD -

If rear inboard strobes are present, strobes will flash at a rate of 70 flashes per minute.

Alternate Flash Pattern

Connect the RED and BROWN/BLACK wires in the 14 wire cable to +12 VDC through a user supplied switch. This mode overrides

REAR ONLY MODE.

4 - HEAD - Both front and rear inboard and outboard strobes on each side will flash at a minimum rate of 70 flashes per minute.

2 - HEAD - Front or rear inboard strobes will flash at a rate of 70 flashes per minute.

Pursuit Flash Pattern

Connect the RED and YELLOW/BLACK wires in the 14 wire cable to +12 VDC through a user supplied switch. This mode overrides

ALL OTHER MODES.

4 - HEAD - Front inboard and outboard strobes on each side will flash at a minimum rate of 70 flashes per minute.

2 - HEAD - If front inboard strobes are present, strobes will flash at a rate of 70 flashes per minute.

5

Driver's Side Rear

Passenger's Side Rear

Driver's Side Front

Passenger's Side Front

Control Wire

Harness

(YEL/BLK,

Supply Ground

Fuse Holder and

+12VDC /+24VDC (RED)

Figure 5

OPTIONAL HALOGEN LIGHTING CONNECTIONS (See wire tag attached to the lightbar cable.)

Take Down Lights - The front facing Clear Halogen Takedown Lights will operate. Connect the WHITE wire in the 14 wire cable to +12 VDC through a user supplied switch.

Drivers Side Alley Light - The drivers side Clear Halogen Alley Light will operate. Connect the

ORANGE wire in the 14 wire cable to +12 VDC through a user supplied switch.

Passenger Side Alley Light - The passengers side Clear Halogen Alley Light will operate. Connect the

YELLOW wire in the 14 wire cable to +12 VDC through a user supplied switch.

Front Intersection Lights - The front facing Intersection Lights will operate. Connect the BROWN wire in the

14 wire cable to +12 VDC through a user supplied switch.

Halogen Rotator - The rotators will operate. Connect the Red, Brown, or Green wires in the 14-wire cable to

+12 VDC through a user supplied switch.

Rear Intersection Lights / Spare Halogen Device - The rear facing Intersection Lights, or any other halogen optional lights will operate. Connect the Green wire in the 14 wire cable to +12VDC through a user supplied switch.

Flashing Halogen Lights - All halogen lights connected to the flasher will alternate at a rate of 115 fpm.

Connect the PURPLE wire in the 14 wire cable to +12 VDC through a user supplied switch.

6

Table 1

A) MODEL 861ADK FLASH PAT-

TERN - REAR AND

ALTERNATE (710)

B) MODEL 862ADK FLASH PAT-

TERN - REAR AND

ALTERNATE (711)

C) MODEL 860ADK, 861ADK, 862ADK

FLASH PATTERN - (PURSUIT)

D) MODEL 860ADK FLASH PAT-

TERN -WIG WAG, REAR AND

Optional Model 860ADK Series Flasher - Refer to Table 1, (A), (B), (C) or (D) for descriptions of possible flash patterns. Connect the Purple wire in the 14 wire cable to +12 VDC.

"Rear Only" Flash Mode - Only the rear facing halogen lights will operate. Connect the PURPLE/

BLACK wire in the 14 wire cable to +12 VDC through a user supplied switch.

"Front & Rear" Flash Mode - Both the front and rear facing halogen lights will operate. Connect the

PINK/BLACK wire in the 14 wire cable to +12 VDC through a user supplied switch.

"Pursuit" Flash Mode - Both the front and rear facing halogen lights will operate together at a rapid rate. Connect the WHITE/BLACK wire in the 14 wire cable to +12 VDC through a user supplied switch.

STROBE MODEL WIRING INSTRUCTIONS

(See wire tag attached to lightbar cable for optional wiring instructions.)

14 WIRE CONTROL CABLE

WIRE COLOR

BLACK

RED

RED & BROWN/BLACK

RED & YELLOW/BLACK

WHITE (OR WHITE/BLK)

YELLOW

ORANGE

BROWN

GREEN

PURPLE

PURPLE/BLACK

PINK/BLACK

WHITE/BLACK

7

FUNCTION

CONNECT TO VEHICLE BATTERY GROUND (-) (EARTH)

OR VEHICLE CHASSIS

STROBE - REAR ONLY

STROBE - ALTERNATING PATTERN (LEFT/RIGHT)

STROBE - INTERCLEAR (PURSUIT)

HALOGEN - TAKE DOWN

HALOGEN - PASSENGER ALLEY LIGHT

HALOGEN - DRIVERS ALLEY LIGHT

FRONT INTERSECTION LIGHTS

REAR INTERSECTION LIGHTS / SPARE

FLASHER ON (+12 VDC AT ALL TIMES)

FLASHER ("REAR ONLY")

FLASHER ("FRONT & REAR" ALTERNATE)

FLASHER ("PURSUIT" MODE)

The flasher wiring is progressive. Individual control wires can be progressively wired to 12 volts through either an individual or a progressive type switch. The priority for the progressive wiring is as follows.

1. TAKEDOWN LIGHTS (Will override any other flashing mode when activated)

2. PURSUIT MODE (Overrides front & rear and rear only modes)

3. FRONT & REAR MODE (Overrides rear only mode)

4. REAR ONLY MODE

Table 2

RECOMMENDED SWITCH CONTROL MINIMUM WIRE SIZES

(Based on 15-Foot Wire Run)

AMP DRAW MIN. WIRE SIZE

Below 8

9-13

14-21

22-36

37-56

#16 AWG

#14 AWG

#12 AWG

#10 AWG

#8 AWG

Table 3

AMP DRAW PER MODULE

Strobes

- (4) Corner Strobes 9 Amps

- (4) Corner Strobes & (4) 4" Strobes 18 Amps

Halogen

- Flashing 4" Halogens

- Arrowstik

- Intersection Light

- Alley Light

- Take Down Light

- Oscilaser

- Rotator

1 Amp ea.

8 Amps avg.

4 Amps ea.

4 Amps ea.

2 Amps ea.

4 Amps ea.

4 Amps ea.

SPEAKER WIRING CONNECTION

If the lightbar has a speaker section, the blue wires attached to the siren amplifier and are to be connected in accordance with the siren manufacturer's instructions. Test the unit for proper operation.

!

WARNING!

Operation of a siren with a live speaker can inflict hearing damage. Always use hearing protection.

Figure 6

8

ARROWSTIK CONTROL HEAD WIRING

The XS-8000 Arrowstik offers a bright, highly visible signal with a reasonable power draw, a maximum of 17 amps at the peak of its cycle, with an average of only 8 amps in any of its four modes. Its solid state design and the absence of moving parts make it virtually repair-free. Replacing lamps is the only maintenance required in normal operation.

The XS-8000 Arrowstik comes complete with its own control box, which is designed to mount in an accessories tree with a siren or by itself. The unit's outputs switch in a directional arrow manner; Arrow Left,

Arrow Right, Center Out, and Random Flash. The directional pattern is chosen via the four position rotary switch. An external Random Flash input is also included for use with the Code 3 InterClear feature or other

+12 VDC input signal.

WIRING INSTRUCTIONS

The only significant difference between your XS-8000 Arrowstik and a conventional XS-8000, is the additional, thinner cable exiting the bottom of the lightbar. The larger cable is your lightbar power cable.

CONTROL HEAD INSTALLATION - After installation of the XS-8000 Lightbar, route the smaller of the two power cables through the vehicle to the location chosen for the control head. Cut the cable to length and strip back the outer insulation to expose the seven colored wires. Strip back 1/8" - 1/4" of colored insulation from each of the wires in the cable. Connect these wires to the seven position terminal plug enclosed in the user parts pack, according to the diagram on the bottom of the control head. The hookup scheme can also be found in Figure 5. Run a 12 gauge wire from the vehicles +12 VDC battery terminal to the 2 red wires in the 7 wire cable. Connect the BLACK, ground (earth) wire, exiting from the rear of the control head, to the vehicle's

Negative (ground, earth) battery terminal, or suitable chassis ground (earth). Crimp the insulated male quickslide, enclosed in the user parts bag, to the end of this wire.

OPTIONAL - Connect the 'EXTERNAL FLASH' terminal to a switched +12 VDC source to activate the

'Random Flash' mode when desired. This input can be connected directly to a Code 3 siren's Interclear output or to one of the Progressive Switch positions on a V-Con Siren Lighting Board for additional lighting under certain circumstances.

OPERATION

The ArrowStik is 'Off' when the on/off push-button is out. Pushing the on/off button in will activate whatever is chosen by the rotary switch.

The LED's on the front of the control head mimic the actions of the ArrowStik to insure proper selection of the pattern chosen. Note: In the 'Arrow Left' mode, the far right lamp (Right Arrowhead) and its corresponding

LED will not be lit. In the 'Arrow Right' mode, the far left lamp (Left Arrowhead) and its corresponding LED will not be lit.

EXTERNAL FLASH OPERATION

Connect the "External Flash" input of the 7 position connector to +12 VDC through a user supplied switch, as shown in Figure 5. When this switch is closed, the Arrowstik will operate in the "Flash" mode, unless another traffic directing pattern is already selected.

OPTIONS

The following are optional features that may or may not be included in your control head depending upon which model you purchased.

"Fast Speed" Mode: Pushing the button marked "Fast" will cause each of the 4 patterns of the Arrowstik to operate at a faster rate, with the same amount of light intensity.

"Aux" Mode: Pushing the button marked "Aux" will activate the control head internal relay. This will switch

+12 VDC to the terminal marked "Aux Output" in Figure 6. The red LED on the front panel will also come on.

This indicates that the auxiliary switch is on. This output is limited to 12 Amps at 12.8 volts nominal.

Maintenance

LENS CLEANING

Use only plain water and a soft cloth, or Code 3 lens polish and a very soft paper towel or facial tissue:

Because plastic scratches easily, cleaning is recommended only when necessary (about every six months).

Do not subject the lenses to car washes that use brushes, as these will scratch the lenses. Use only Code 3 approved cleaning/polishing agents, many chemicals damage lenses and reduce lighting effectiveness.

9

!

WARNING!

High voltages and /or temperatures are present inside the unit. Disconnect from power and wait 10 minutes prior to servicing or troubleshooting. Use hand and eye protection when changing halogen lamps or flashtubes.

CHANGING LAMPS

First, remove the 2 screws from the end of the lightbar, these attach the end cap of the outboard lens to the frame. Second, remove the 2 screws and washers from the top center of the lightbar. Lift the lens assembly off slowly to prevent damaging any of the internal assemblies.

!

WARNING!

Lamps are extremely hot! Allow to cool completely before attempting to remove. Gloves and eye protection should be worn when handling halogen lamps or flashtubes as they are pressurized and accidental breakage can result in flying glass.

Remove the lens as explained above. Next inspect the lamp and compare to Figure 5 to determine lamp type. It may be necessary to remove any filters to make access easier.

H1: First grasp lamp at base and turn until retaining clip tab is accessible. Using a blade screwdriver, remove retaining clip and pull lamp straight up. Replace with new lamp. Insure that the power lead and retaining clip is fully inserted.

Bi-pin Halogen: See Figure 7. First disconnect the reflector from the frame by removing the 2 screws holding down the rear legs. Disconnect the front of the reflector from its filter and lift from frame. Disconnect wire connectors from lamp leads, bend lamp leads straight and pull free from reflector. Install new lamp and seat into reflector socket, bend lamp leads and attach wire connectors. Engage front of reflector with its filter and set onto frame. Install 2 hold down screws onto rear reflector legs.

Figure 7

Figure 8

CATHODE

WIRE (-)

TRIG-

GER

WIRE

ANODE

WIRE

(+)

Figure 9

10

Helical Strobe Tube: See Figure 9. First disconnect the reflector from the frame by removing the 2 screws holding down the rear legs. Disconnect the front of the reflector from its filter and lift from frame. Disconnect tube leads from mechanical connectors, bend tube lead straight and pull free from reflector. Install new tube, with rubber grommets on tube ends, and seat into reflector. Bend tube leads and reconnect to same mechanical connectors. Make sure that positive and negative tube leads are connected to similarly

charged component ends. Engage front of reflector with its filter and set onto frame. Install 2 hold down screws onto rear reflector legs.

!

WARNING!

If attempting to clean the reflector, use only a mild glass cleaner and a very soft cloth. Do not attempt to use any wax type products as these will burn onto the reflector and impair effectiveness.

Strobe Filter Replacement

Refer to figure 10. The filter can be removed by unsnapping it from the light head and by bending back the mirror slightly for clearance. Prying the filter from the front may damage the glass strobe tube or reflector.

To replace the filter, reverse the above procedure. The filter should be fully engaged on the light head assembly. Care should be taken to not damage the strobe tube or to scratch the reflective surface of the reflector when replacing the filter.

Strobe Light Head Replacement

Refer to figure 10. Disconnect the light head assembly from the strobe power supply and remove the filter if any. Unfasten the screws attaching the light head mounting bracket to the light bar chassis and remove the light head from the light bar. On a bench or other work suitable work surface unfasten the screws attaching the strobe light head assembly from the light head mounting bracket. Install the new strobe light head assembly to the light head mounting bracket and reinstall the light head back onto the light bar chassis. Reconnect the light head wiring to the strobe power supply and reattach the filter. It is important to reroute and secure the wiring as close as possible to its original position.

Strobe Lighthead

Assembly

Filter (if supplied)

FIGURE 10

11

Troubleshooting

All XS 8000 Strobe Lightbars are thoroughly tested prior to shipment. However, should you encounter a problem during installation or during the life of the product, follow the guide below for information on repair and troubleshooting. Additional information may be obtained from the factory technical help line at 314-426-2700 ext. 2132.

NOTHING IN THE LIGHTBAR OPERATES - Check the following: 1) The vehicle battery 2) Connection of the BLACK wire at battery NEGATIVE (-) (earth).

NO STROBE LIGHTS IN THE LIGHTBAR OPERATE - Check the following: 1) +12 VDC source connection for the control switch box and any in line fuse 2) Connection of the RED wire to +12VDC at the control switch box 3) 15 Amp fuse located on a pigtail connected to each power supply located on one or both sides of the lightbar. If the 15 Amp fuse is blown, replace it with another 15 Amp fuse and test the lightbar. If the fuse continues to blow, return the power supply only, NOT the entire lightbar, to the factory for service ( see back page of this manual for product return instructions. For instructions on removal of an electronic device from the lightbar, see the "Electronics Module Removal" section in this manual.

!

WARNING!

Do not replace the fuse with one of a higher rating. This will damage the power supply and void all warranties.

ONE STROBE LIGHT MODULE DOES NOT OPERATE - 1) Replace the defective strobe light module by switching it with a module that is known to be working 2) Replace the 3 circuit output cable between the power supply and light module, with a cable that is known to be working.

12

PROBLEM

Arrowstik does not function when turned on.

XS-8000 ArrowStik

TROUBLE SHOOTING GUIDE

QUESTION

Are LED's functioning properly?

Yes

CAUSE

Plug in rear of control box is loose or disconnected.

No Poor ground (earth) connection.

Power from battery has been disconnected or the control box has been damaged.

REMEDY

Reconnect plug.

Reconnect ground (earth).

Check connections at the battery and plug.

If connections are good and voltage is at least 10 volts, the control box has been damaged. Return to CODE3 for repair.

Lamp does not come on when it should.

Are LED's functioning properly?

Yes

No

Lamp has burned out.

Bad wiring connection.

Replace lamp.

Repair connection as in

Figure 5.

Return to CODE3 for repair.

Control box has been damaged.

Normal operation.

None

Outer lamps do not come on in Arrow Left mode or

Arrow Right mode.

Arrowstik runs opposite than the selected pattern.

Are LED's functioning properly?

Yes

Lamp looks dim.

No

Arrowstik is upside down.

Defective wiring.

Control box damaged.

Defective lamp

Low voltage

Poor ground (earth)

Product in in "Dim" mode.

Check that the cable exit is on the driver's side.

Repair or return to CODE3.

Repair or return to CODE3.

Replace lamp.

Check connections or battery.

Check ground (earth) and wire gauge.

Select appropriate mode.

MULTIPLE STROBE MODULES DO NOT OPERATE - Check the following: 1) 15 Amp fuse on the power supply on that side of the lightbar. If the 15 Amp fuse continues to blow, return the power supply only, NOT the entire lightbar, to the factory for service. For instructions on removal of an electronic device from the lightbar see the "Electronics Module Removal" section in this manual.

PASSENGER SIDE AND DRIVER SIDE DO NOT FLASH IN THE SAME MODE - Check that the four wire connector is secured to each power supply. The power supply must be removed from the frame and turned over to inspect this connection.

ONE TAKE DOWN LIGHT DOES NOT OPERATE - Check the following: 1) Halogen lamp in suspect reflector

2) Wiring connections on leads of suspect halogen lamps - individual Red and Black wires for each lamp.

BOTH TAKE DOWN LIGHTS DO NOT OPERATE - Check the following: 1) Halogen lamp in suspect reflector

2) Wiring connections on leads of suspect halogen lamps - individual Red and Black wires for each lamp. 3)

WHITE wire in 14 wire control cable at switch box for +12 VDC when activated.

PASSENGER SIDE ALLEY LIGHT DOES NOT OPERATE - Check the following: 1) Halogen lamp in

Passenger side Alley Light assembly 2) Wiring connections on rear of Alley Light assembly - individual Black wires with crimped sockets slide over each lead of suspect lamp 3) YELLOW wire in 14 wire control cable at switch box for +12 VDC when activated.

13

BOTH SIDES FLASH IN ONLY REAR ONLY - Check that the three wire connector from the lightbar cable to the power supply is connected properly.

DRIVER'S SIDE ALLEY LIGHT DOES NOT OPERATE - Check the following: 1) Halogen lamp in Passenger side Alley Light assembly 2) Wiring connections on rear of Alley Light assembly - individual Black wires with crimped sockets slide over each lead of suspect lamp 3) YELLOW wire in 14 wire control cable at switch box for +12 VDC when activated.

ROTATOR LAMP DOES NOT OPERATE - Check the following: 1) Halogen lamp in particular rotator in question. 2) Wiring connections at each rotator.

3) RED, BROWN, or GREEN wire in 14-wire control cable at switch box for +12 VDC when activated.

OSCILASER ® OR INTERSECTION LIGHT DOES NOT OPERATE - Check the following: 1) Halogen lamp in particular assembly in question 2) wiring connections at each assembly 3) BROWN or GREEN wire in 14 wire control cable at switch box for +12 VDC when activated.

ALL FLASHING HALOGEN LIGHTS DO NOT OPERATE - Check the following: 1) 10 Amp fuse (red) on flasher module. The flasher module is located on the passenger side of the lightbar 2) PURPLE wire in 14 wire control cable at switch box for +12 VDC when activated.

ONE FLASHING HALOGEN LIGHT DOES NOT OPERATE - Check the following: 1) Halogen lamp in suspect reflector 2) Wiring connections on leads of suspect halogen lamps - individual Red and Black wires for each lamp.

For 860ADK Series Flasher trouble shooting, refer to wiring instructions on Page 5 of this manual.

Electronics Module Removal

In the event that a power supply or flasher must be returned to the factory for service, disconnect the wiring from the unit and bend the wiring back out of the way. All connectors are locking and polarized to minimize confusion when replacing a module. However, one may wish to mark each connector as they are disconnected to make reconnection faster and less confusing. This can be done using a permanent marker and masking tape or simple sketch or chart.

Using a #2 Phillips-head screwdriver or 1/4" socket, remove the screws at each end of the electronics module.

Remove screw connecting the ( BLK ) ground wire to the frame. Now lift the module up off of the frame and replace it with a new module. Power supplies also have two capacitors attached to the electronics which are held down with a separate bracket to the frame.

To reconnect the new module, simply connect each wire removed following the markings made on each wire in the removal step above. When installing the capacitors to the frame, be very careful to position the capacitors with the terminals pointed outward to avoid shorting them to the capacitor bracket tabs.

Installing New Filters or Take Down/Work light

When installing new filters in the center section of the 48" length bar (83XXAR) a modification must be made to the filters. The edge of the filter adjoining the frame bulkhead must be trimmed approximately 1/10". This can be done using an ordinary pair of household scissors. Care must be taken to trim only the edge on the side of the filter adjoining the frame bulkhead. (See Figure

11)

When installing Take Down or Work Lights a special clip must be used to secure the front of the reflector in lieu of the filter.

They are included with the Take Down or

Work Light when ordered from the factory.

Field conversion of a filtered stationary to a Take Down may be done by simply removing the optic portion of the filter from the mounting feet. A fine tooth saw or tin snips may be used to cut the filter.

Trim Approximately 1/10"

48" Bar Only

(Not Required for 56" or 74" Bars)

14

Figure 12

Parts & Exploded Views

2

3

Parts List

Ref No.

Description

1 Outboard Lens Assembly

Center Lens Assembly (Short)

Frame Assembly (48" Bar)

Frame

Bulkhead

Locator Strip

15

Part No.

S50141 (Clear)

S50142 (Red)

S50143 (Blue)

S50144 (Amber)

S50151 (Clear)

S50152 (Red)

S50153 (Blue)

S50154 (Amber)

S50053

T03389

T03330

S50103

11

12

13

14

6

7

8

REF NO.

4

5

9

10

15

16

DESCRIPTION

Alley Light

50 watt MR16 bulb

Intersection Light - D.S. Rear or P.S. Front

-P.S. Rear or D.S. Front

55 watt H1 lamp

Strobe Lighthead Assembly -

End Signal Position

Strobe Lighthead Assembly -

End Signal Position Mirror - DS Frt/PS Rr

Strobe Lighthead Assembly -

End Signal Position Mirror - PS Frt/DS Rr

Strobe Light Head Assy – End Signal Pos Filter

Red

Blue

Amber

Strobe Light Head Assembly – Directional Position

Strobe Light Head Assy – Directional Pos Filter

Red

Blue

Amber

4" Strobe Reflector Assembly

4" Halogen Reflector Assembly

4" ADK Flasher Halogen Reflector Assembly

27 watt bi-pin lamp

Curved Filter without Optics

Red

Blue

Amber with Optics

C;ear

Red

Blue

Amber

Straight Filter with Optics

Clear

Red

Blue

Amber

Intensity CCI Power Supply - 4HD

Intensity CCI Power Supply - 2HD

Phillips Oval Head Screw

Countersunk Finishing Washer

#8 Hex Head Sheet Metal Screw -

270" long

.375" long

Halogen Rotator Assembly

Diamond/"V" Mirror

16

T02661

T02662

T02663

T02664

S80300

S80307

T03362

T03361

T01215

T00243

S35499

S35501

T02692

T02693

T02694

T02671

T02672

T02673

T02674

PART NO.

S50091

T03715

S50093

S50073

T01543

T09424

T09409

T09406

T09442

T09443

T09444

T09425

T09442

T09443

T09444

S70321

S50070

S50237

T03346

*

*

*

*

*

*

Parts Not Shown

Ref No.

Description

*

Frame Assembly (56" Bar)

Frame

Locator Strip

Frame Assembly (74" Bar)

Frame

Locator Strip

Center Lens Assembly (Long)

860ADK Flasher

861ADK Flasher

862ADK Flasher

15' Strobe Power/Control Cable

Part No.

S50054

T03390

S50116

S50055

T03391

S50137

S50161 (Clear)

S50162 (Red)

S50163 (Blue)

S50164 (Amber)

S70223

S70224

S70225

S50196

17

WARRANTY

Code 3, Inc. emergency devices are tested and found to be operational at the time of manufacture.

Provided they are installed and operated in accordance with manufacturer's recommendations, Code 3,

Inc. guarantees all parts and components except the lamps to a period of 1 year (unless otherwise expressed) from the date of purchase or delivery, whichever is later. Units demonstrated to be defective within the warranty period will be repaired or replaced at the factory service center at no cost.

Use of lamp or other electrical load of a wattage higher than installed or recommended by the factory, or use of inappropriate or inadequate wiring or circuit protection causes this warranty to become void.

Failure or destruction of the product resulting from abuse or unusual use and/or accidents is not covered by this warranty. Code 3, Inc. shall in no way be liable for other damages including consequential, indirect or special damages whether loss is due to negligence or breach of warranty.

CODE 3, INC. MAKES NO OTHER EXPRESS OR IMPLIED WARRANTY INCLUDING, WITH-

OUT LIMITATION, WARRANTIES OF FITNESS OR MERCHANTABILITY, WITH RESPECT TO

THIS PRODUCT.

PRODUCT RETURNS

If a product must be returned for repair or replacement*, please contact our factory to obtain a Return

Goods Authorization Number (RGA number) before you ship the product to Code 3, Inc. Write the RGA number clearly on the package near the mailing label. Be sure you use sufficient packing materials to avoid damage to the product being returned while in transit.

*Code 3, Inc. reserves the right to repair or replace at its discretion. Code 3, Inc. assumes no responsibility or liability for expenses incurred for the removal and / or reinstallation of products requiring service and/or repair.; nor for the packaging, handling, and shipping: nor for the handling of products return to sender after the service has been rendered.

NEED HELP? Call our Technical Assistance Hotline - (314) 996-2800

Code 3, Inc.

10986 N. Warson Road

St. Louis, Missouri 63114-2029—USA www.code3pse.com

Revision 9, 02/2006 - Instruction Book Part No. T03373

©2001-6 Code 3, Inc. Printed in USA

Intensity is a trademanr and Code 3 is a registered trademark of Code 3, Inc. a subsidiary of Public Safety Equipment, Inc.